2006 FORD GALAXY engine

Engine Emi\b\bion Cont\fol - 2.0L Du\fatec-
HE (107kW/145PS) - MI4/2.0L Du\fatec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Du\fatec-HE (118kW/160PS) - MI4 -
Engine Emi\b\bion Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
Gene\fal Equipment
In\bpection and Ve\fification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\bual In\bpection Cha\ft
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
S
ymptom\fCh\brt.\f
Symptom Cha\ft
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b

Hose(s)/hose\fjoints\f\f

G\bsket(s)\f\f

Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f\f

PCV\fsep\br\btor\f\f

Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\f
Electric\bl\fconnector(s)\f\f

Wiring\fh\brness\f\f

Fuse(s)\f\f

Rel\by\f\f

EGR\fv\blve\f\f

Powert\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Poor\fengine\f
perform\bnceEGR\fv\blve.\f
*Using\fthe\fWDS,\fCHECK\fthe\fEGR\fV\blve\fDuty\fCycle\finput\f
sign\bl\fto\fthe\fEGR\fv\bcuum\fregul\btor\fv\blve.\fIf\fthe\fresult\fis\f
0%,\fREMOVE\fthe\fEGR\fv\blve.\f\f
REFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-
08A

\fEngine\fEmission\fControl\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSPECT\fthe\fEGR\fv\blve\f\bnd\fv\blve\fse\bt\ffor\fd\bm\bge.\fM\bke\f
sure\fth\bt\fthe\fEGR\fv\blve\fis\fin\fthe\fclosed\fposition.\fIf\fthe\f
EGR\fv\blve\fis\fnot\fclosed.\fINSTALL\f\b\fnew\fEGR\fv\blve.\fTEST\f
the\fsystem\ffor\fnorm\bl\foper\btion.\fIf\fthe\fresult\fis\fnot\f0%\f
continue\fthe\fengine\fdi\bgnostic\fusing\fthe\fWDS.\f
*
Excessive\f
cr\bnkc\bse\f
pressureBlocked\for\f
d\bm\bged\fPCV\f
hose(s).\f Blocked\f
cr\bnkc\bse\fvent\f
oil\fsep\br\btor.\f
*
*CHECK\fthe\fPCV\fsystem\fcomponents\ffor\fblock\bges,\fCLEAN\f
or\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f
*
Worn\for\f
d\bm\bged\f
engine\f
components.\f
*REFER\fto:\fEngine\f(303-01A,\fDi\bgnosis\f\bnd\fTesting).\f
*
Стр. 1 из 1
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Engine Emi\b\bion Cont\fol - 2.0L Du\fatec-
HE (107kW/145PS) - MI4/2.0L Du\fatec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L
Du\fatec-HE (118kW/160PS) - MI4 -
Exhau\bt Ga\b Reci\fculation (EGR) Valve
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Gene\fal Equipment
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
In\btallation
Hose\fcl\bmp\fremover/inst\bller 1. Dr\bin\fthe\fcooling\fsystem.\fRefer\fto:\f Cooling\fSystem\fDr\bining,\fFilling\f\bnd\f
Bl e

eding \f(303-03A\fEngine\fCooling\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-
HE\f(118kW/160PS)\f-\fMI4,\fGener\bl\fProcedures).\f
2. \f
3. \f
4. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d
\b

m\bged.\f
General \bqui\fment: Ho
se\fcl\bmp\f
rem
over/inst\bller \f
Tor

que: 25\fNm
\f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\fm\bting\f
f \b

ces\f\bre\fcle\bn\f\bnd\ffree\fof\fforeign\fm\bteri\bl.\f
To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
\f\f
Стр. 1 из 1
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Engine Emi\b\bion Cont\fol - 2.5L Du\fatec
(162kW/220PS) - VI5 - Engine Emi\b\bion
Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bc\fiption and Ope\fation
2.5L Du\fatec-ST (VI5)
Engine Emi\b\bion Component\b
\f\f
De\bc\fiption
Int\bke\fm\bnifold\fto\fturboch\brger\fbre\bther\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fto\fv\blve\fcover\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fto\fint\bke\fm\bnifold\fhose\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\f
Item
1
2
3
4
\f
Pa\ft Numbe\f -
-
-
-
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510285&gui...procarmanuals.com
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Engine Emi\b\bion Cont\fol - 2.5L Du\fatec
(162kW/220PS) - VI5 - Engine Emi\b\bion
Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
In\bpection and Ve\fification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\fd\bm\bge.\f
V

i\bual In\bpection Cha\ft
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Cha\ft
Mechanica\bE\bectrica\b

Hose(s)/hose\fjoints\f\f

G\bsket(s)\f\f

Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fv\blve\f\f

PCV\fcr\bnkc\bse\fvent\foil\fsep\br\btor\f\f

Turboch\brger\f
Electric\bl\fconnector(s)\f\f

Wiring\fh\brness\f\f

Fuse(s)\f\f

Rel\by\f\f

Powert\bin\fcontrol\fmodule\f(PCM)\f
\fymptomPossib\be \fourcesAction
Excessive\f
cr\bnkc\bse\f
pressureBlocked\fPCV\fcr\bnkc\bse\f
vent\foil\fsep\br\btor.\f
Blocked\fPCV\fhose.\f
*
*CLEAN\for\fINSTALL\fnew\fPCV\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
Worn\for\fd\bm\bged\f
engine\fcomponents.\f
*REFER\fto:\fEngine\f(303-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Oil\fin\fthe\f\bir\f
int\bke\fsystemCr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*CLEAN\for\fINSTALL\f\b\fnew\fcr\bnkc\bse\fvent\foil\f
sep\br\btor.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
*
Turboch\brger\f
*REFER\fto:\fTurboch\brger\f(303-04E,\fDi\bgnosis\f
\bnd\fTesting).\f
*
Worn\for\fd\bm\bged\f
engine\fcomponents.\f
*REFER\fto:\fEngine\f(303-01B,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Стр. 1 из
1
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Engine Emi\b\bion Cont\fol - 1.8L Du\fato\fq-
TDCi (74kW/100PS) - Lynx/1.8L
Du\fato\fq-TDCi (92kW/125PS) - Lynx -
Engine Emi\b\bion Cont\fol
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\bc\fiption and Ope\fation
\f\f
De\bc\fiption
EGR\fv\blve\f
EGR\fcooler\fto\fint\bke\fm\bnifold\fg\bsket\f
EGR\fcooler\f
Exh\bust\fm\bnifold\fto\fEGR\fcooler\ftube\fg\bsket\f
The\fEGR\fsystem\f\bllows\f\b\fme\bsured\fqu\bntity\fof\fexh\bust\fg\bs\fto\fbe\fdirected\fb\bck\fto\fthe\f
in
t\bke\fm\bnifold.\fThe\fexh\bust\fg\bs\fis\fintroduced\fto\fthe\fincoming\fch\brge\f\bir\fin\fthe\fint\bke\f
m\bnifold,\fwhere\fit\fmixes\fwith\fthe\f\bir/fuel\fmixture\f\bnd\flowers\fthe\fpe\bk\fg\bs\ftemper\bture,\f
reducing\fnitrogen\foxide\f(NOx)\fexh\bust\femissions.\fThe\fEGR\fv\blve\fis\felectric\blly\foper\bted\f
\bnd\fis\fcontrolled\fthrough\f\bn\finput\ffrom\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\f
The\fEGR\fsystem\fis\ffitted\fwith\f\bn\fEGR\fcooler.\fThe\fEGR\fcooler\freduces\fthe\ftemper\bture\fof\f
the\fexh\bust\fg\bsses\fbeing\freturned\fto\fthe\fint\bke\fsystem.\fBy\freducing\fthe\fEGR\ftemper\bture,\f
the\fint\bke\f\bir\fch\brge\fdensity\fis\fnot\f\bdversely\f\bffected,\fso\fm\bint\bining\fthe\foptimum\ffueling\f
ch\br\bcteristics.\f\f Item
1
2
3
4
\f
Pa\ft Numbe\f -
-
-
-
Стр. 1 из 3
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Engine Emi\b\bion Cont\fol - 1.8L Du\fato\fq-
TDCi (74kW/100PS) - Lynx/1.8L
Du\fato\fq-TDCi (92kW/125PS) - Lynx -
Engine Emi\b\bion Cont\fol—
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\bi\b and Te\bting
Gene\fal Equipment
P\finciple\b of Ope\fation
Exhau\bt Ga\b Reci\fculation (EGR) \by\btem
To\fm\bint\bin\fthe\fst\bnd\brds\fof\flow\fexh\bust\femission\flevels\frequired\fof\ftod\by's\fengines,\fthe\f
EG

R\fsystem\fon\fthis\fengine\fis\ffully\felectronic\blly\fcontrolled.\f
The\fEGR\fv\blve\fis\f\b\fproportion\bl\felectric\fmotor\fcontrolled\fdirectly\fby\f\b\fduty-cycle\fsign\bl\f
from\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM).\fIntegr\bted\finto\fthe\fEGR\fv\blve\fis\f\b\fv\blve\fposition\f
sensor.\fThe\fsign\bl\ffrom\fthe\fEGR\fv\blve\fposition\fsensor\f\bllows\ffor\fthe\fprecise\fcontrol\fof\fthe\f
timing\f\bnd\fthe\fqu\bntity\fof\fexh\bust\fg\bs\fto\fbe\frecircul\bted.\fIf\fthe\fEGR\fv\blve\fbecomes\f
inoper\btive\for\ff\bils\fto\fclose\fcompletely,\fthe\fPCM\fwill\fr\bise\f\b\fdi\bgnostic\ftrouble\fcode\f(DTC)\f
\bnd\fthe\finstrument\fcluster\fm\blfunction\findic\btor\fl\bmp\f(MIL)\fwill\fbe\fillumin\bted.\f\f
If\f\b\fnew\fEGR\fv\blve\fis\finst\blled.\fThe\fb\bse\fsetting\f(closed\fposition)\fv\blue\fmust\fbe\fconfigured\f
to\fthe\fPCM.\fThis\fis\finiti\bted\fusing\fWDS.\fIf\fthe\fb\bse\fsetting\fis\fnot\fconfigured\fto\fthe\fPCM,\fthe\f
setting\ffrom\fthe\fprevious\fEGR\fv\blve\fwill\fbe\fused\f\bnd\fthe\fcontrol\ffunction\fof\fthe\fEGR\f
system\fwill\fbe\fincorrect.\f
The\fEGR\fsystem\fis\ffitted\fwith\f\bn\fEGR\fcooler.\fThe\fEGR\fcooler\freduces\fthe\ftemper\bture\fof\f
the\fexh\bust\fg\bsses\fbeing\freturned\fto\fthe\fint\bke\fsystem.\fBy\freducing\fthe\fEGR\ftemper\bture,\f
the\fint\bke\f\bir\fch\brge\fdensity\fis\fnot\f\bdversely\f\bffected,\fso\fm\bint\bining\fthe\foptimum\ffueling\f
ch\br\bcteristics.\f
Po\bitive C\fankca\be Ventilation (PCV) \by\btem
\f\f
De\bc\fiption
PCV\fv\blve\fcover\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)\f(418-
F224)
Item 1
\f
Pa\ft Numbe\f -
-
Стр. 1 из 4
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G860267&gui...procarmanuals.com
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PCV\fv\blve\fdi\bphr\bgm\f
PCV\fv\blve\fbush\f
PCV\fv\blve\fspring\f
V\blve\fcover\f
The\fPCV\fsystem\fis\fm\bde\fup\fof\f\bn\foil\fsep\br\btor\fch\bmber\fconnected\fto\fthe\fcr\bnkc\bse\f\bnd\f
v\b
lve\fcover\fby\fhoses.\f
The\fcr\bnkc\bse\fpressure\fis\fcontrolled\fby\f\b\fdi\bphr\bgm\foper\bted\fPCV\fv\blve\fbuilt\finto\fthe\fv\blve\f
cover.\fAs\fthe\fpressure\fin\fthe\foil\fsep\br\btor\freduces,\fthe\fdi\bphr\bgm\fv\blve\fcloses\f\bg\binst\fthe\f
force\fof\fthe\fPCV\fv\blve\fspring,\fso\fclosing\fthe\fPCV\fv\blve.\fAs\fthe\fcr\bnkc\bse\fpressure\frises,\fthe\f
PCV\fv\blve\fis\fpushed\fopen\f\bssisted\fby\fthe\fPCV\fv\blve\fspring.\fThis\f\bllows\fthe\fpositive\f
cr\bnkc\bse\fg\bsses\fto\fbe\fsc\bvenged\fby\fthe\f\bir\fint\bke\fsystem.\f
In\bpection and Ve\fification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

i\bual In\bpection Cha\ft
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(
if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fdi\bgnostic\f
t
rouble\fcode\f(DTC)\fch\brt.\f
Diagno\btic T\fouble Code (DTC) Index Cha\ft
1. 1.
If\fno\fDTC's\f\bre\fretrieved,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fsymptom\fch\brt.\f
S

ymptom Cha\ft
Pinpoint Te\bt\b 2
3
4
5
Mechanica\bE\bectrica\b

Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\f\f

EGR\fcooler\f\f

G\bsket\f\f

PCV\fhoses\f\f

PCV\foil\fsep\br\btor\f
Electric\bl\fconnector\f\f

Wiring\fh\brness\f
\fTC\fescription/ConditionPossib\be SourceAction
P1402EGR\fmetering\forifice\frestricted\fEGR\fv\blve\fstuck\fclosed\for\fle\bkingGO\fto\fPinpoint\fTest\fA.\f
SymptomPossib\be SourcesAction
Excessive\fexh\bust\f
bl\bck\fsmokeEGR\fv\blve.\f
*GO\fto\fPinpoint\fTest\f A.\f\f
*
Excessive\fcr\bnkc\bse\f
pressureBlocked\for\fd\bm\bged\fPCV\f
hose(s).\f Blocked\fPCV\foil\fsep\br\btor.\f
*
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
Worn\for\fd\bm\bged\fengine\f
components.\f
*REFER\fto:\fEngine\f(303-01C,\f
Di\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE
TEST
CON\fITIONS\fETAILS/RESULTS/ACTIONS
-
-
-
-
Стр. 2 из 4
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A1: CHECK THE EGR VALVE
Using\fthe\fWDS,\fCHECK\ffor\fDTC\fP1402.\f1
Is\fDTC\fP1402\fretrieved?\f
Ye\b INSTALL\f\b\fnew\fEGR\fv\blve.\f\f
REFER\fto:\fExh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve\f(303-08C,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
Continue\fthe\fdi\bgnostic\fusing\fthe\fWDS.\f
PINPOINT TEST B : EXCESSIVE CRANKCASE PRESSURE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
B1: CHECK THE PCV HOSES FOR BLOCKAGE
Remove\fthe\fPCV\fhoses.\f1
Inspect\fthe\fPCV\fhoses\ffor\fblock\bge.\f2
Are\fthe\fPCV\fhoses\ffree\ffrom\fblock\bge?\f
Ye\b GO\fto\fB2.\f\f
No
C

LEAN\for\fINSTALL\fnew\fPCV\fhoses\f\bs\fnecess\bry.\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f\f
B2: CHECK THE PCV VALVE FOR DAMAGE
Inspect\fthe\fPCV\fv\blve\ffor\fd\bm\bge\for\fblock\bge.\f1
Is\fthe\fPCV\fv\blve\fspring\fund\bm\bged\f\bnd\fthe\fPCV\fv\blve\f
free\ffrom\fblock\bge?\f
Ye\b
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\fthe\fconcern\f
persists,\f\f
REFER\fto:\fEngine\f(303-01C,\fDi\bgnosis\f\bnd\fTesting).
\f
\f
\f\f
Стр. 3 из 4
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