Ford Galaxy / Ford S-MAX. Manual — part 441

Engine Emission Control - 2.0L Duratorq-
TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-
TDCi (103kW/140PS) - DW, Emission
Requirements: Stage IV - Exhaust Manifold
to Exhaust Gas Recirculation (EGR) Valve
Tube

S-MAX/Galaxy 2006.5 (02/2006

Print

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1.

2.

1. Torque:

22 Nm

3. Detach

the A
pillar
exterior
trim
panel
lower
clips.

3.

2. Torque:

10 Nm

4.

NOTE: Note the orientation of the clamp to aid
installation.
NOTE: The gaskets are to be reused unless
damaged.

1. Torque: 5 Nm
2. Torque: 10 Nm
3. Discard the clamp.

Installation

4. Torque: 10 Nm

1.

NOTE: Make sure that a new clamp is installed.
NOTE: Make sure that the clamp is installed to the
same orientation as when removed.

To install, reverse the removal procedure.

Engine Emission Control - 2.2L Duratorq-
TDCi (129kW/175PS) - DW - Engine
Emission Control—

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Diagnosis and Testing

General Equipment

Principles of Operation

Exhaust Gas Recirculation (EGR) system

To maintain the standards of low exhaust emission levels required of todays engines, the
EGR system on this engine is fully electronically controlled.

The EGR valve is a proportional electric motor controlled directly by a duty-cycle signal
from the powertrain control module (PCM). Integrated into the EGR valve is a valve position
sensor. The signal from the EGR valve position sensor allows for the precise control of the
timing and the quantity of exhaust gas to be recirculated. If the EGR valve becomes
inoperative or fails to close completely, the PCM will raise a diagnostic trouble code (DTC)
and the instrument cluster malfunction indicator lamp (MIL) will be illuminated. At the end
of each drive cycle the PCM drives the EGR valve to the fully open and fully closed positions
several times. This assists with cleaning the EGR valve.

If a new EGR valve is installed. The base setting (closed position) value must be configured
to the PCM using the Ford approved diagnostic tool. If the base setting is not configured to
the PCM, the setting from the previous EGR valve will be used and the control function of
the EGR system will be incorrect.

The EGR system is fitted with an EGR cooler. The EGR cooler reduces the temperature of
the exhaust gasses being returned to the intake system. By reducing the EGR temperature,
the intake air charge density is not adversely affected, so maintaining the optimum fuelling
characteristics.

Positive Crankcase Ventilation (PCV) system

Description

PCV valve diaphragm

PCV valve

The PCV system is made up of a crankcase vent oil separator chamber connected to the
crankcase by a hose. The crankcase vent oil separator chamber is an integral part of the
intake manifold.

The crankcase pressure is controlled by a diaphragm operated PCV valve built into the
crankcase vent oil separator. As the pressure in the crankcase vent oil separator reduces,
the diaphragm valve closes against the force of the PCV valve spring, so closing the PCV
valve. As the crankcase pressure rises, the PCV valve is pushed open assisted by the PCV
valve spring. This allows the positive crankcase gasses to be scavenged by the air intake
system.

Ford approved diagnostic tool

Item

1

2

Part Number

-

-

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step.

4. 4. If the cause is not visually evident, verify the symptom and refer to the DTC Index

Chart.

5. 5. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to

continue diagnosis.

Diagnostic Trouble Code (DTC) Index Chart

Symptom Chart

Mechanical

Electrical

Exhaust gas recirculation (EGR) valve

EGR tube

EGR cooler

EGR tube clamp

Gasket

PCV hose

Crankcase vent oil separator

Electrical connector

Wiring harness

DTC

Description

Possible

Source

Action

P1412

MIL illuminated

EGR valve

REFER to Excessive exhaust black smoke in

the Symptom Chart

P0404

MIL illuminated

EGR valve

REFER to Excessive exhaust black smoke in

the Symptom Chart

P1335 Powertrain warning indicator

illuminated

EGR valve

REFER to Excessive exhaust black smoke in

the Symptom Chart

Symptom

Possible

Sources

Action

Excessive
exhaust
black
smoke

EGR valve.

*

Using the Ford approved diagnostic tool, CHECK the PCM

calibration. If necessary UPDATE the PCM calibration to the
latest level. Using the Ford approved diagnostic tool,
TOOLBOX/POWERTRAIN SERVICE FUNCTIONS/COMPONENT
OR PARAMETER RESET/EGR RE-CALIBRATION, RESET the EGR
valve. Carry out a road test, if the concern persists GO to
Pinpoint Test

A.

*

Excessive
crankcase
pressure

Blocked or

damaged PCV
hose(s).

Blocked

crankcase
vent oil
separator.

*

*

GO to Pinpoint Test

B.

*

Worn or

damaged
engine
components.

*

REFER to:

Engine

(303-01G Engine - 2.2L Duratorq-TDCi

(129kW/175PS) - DW, Diagnosis and Testing).

*