2006 FORD S-MAX Service Repair Manual

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Page 1737 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.0L Du\fatec- HE (107kW/145PS) - MI4/2.0L Du\fatec- HE Flex Fuel (107kW/145PS) - MI4/2.3L Du\fatec-HE (118kW/160PS) - MI4 - Engine Emi\b\bion Cont\fol S-MAX/G\bl\bxy\f2$

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\fElectric\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
*
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Page 1738 of 4402

Page 1739 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.5L Du\fatec (162kW/220PS) - VI5 - Engine Emi\b\bion Cont\fol S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\bc\fiption and Ope\fation 2.5L Du\fatec-ST (VI5) Engine$

Page 1740 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.5L Du\fatec (162kW/220PS) - VI5 - Engine Emi\b\bion Cont\fol S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagno\bi\b and Te\bting In\bpection and Ve\fification 1. 1$

Page 1741 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 1.8L Du\fato\fq- TDCi (74kW/100PS) - Lynx/1.8L Du\fato\fq-TDCi (92kW/125PS) - Lynx - Engine Emi\b\bion Cont\fol S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f De\bc\fiptio$

Page 1742 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\fDe\bc\fiption V\blve\fcover\f\bnd\fcr\bnkc\bse\fto\fpositive\fcr\bnkc\bse\fventil\btion\f(PCV)\f sep\br\btor\fPCV\fhose\f PCV\fsep\br\btor\fto\fv\blve\fcover\fPCV\fhose\f PCV\fsep\br\btor\f PCV\f$

Page 1743 of 4402

$FORD S-MAX 2006 Service Repair Manual V\blve\fcover\fto\f\bir\fint\bke\fpipe\fPCV\fhose\f PCV\fv\blve\fspring\f\f The\fPCV\fsystem\fconsists\fof\f\bn\foil\fsep\br\btor\fch\bmber\fconnected\fto\fthe\fcr\bnkc\bse\f\bnd\fv\blve\f co ver\fby$

Page 1744 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 1.8L Du\fato\fq- TDCi (74kW/100PS) - Lynx/1.8L Du\fato\fq-TDCi (92kW/125PS) - Lynx - Engine Emi\b\bion Cont\fol— S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagno\bi$

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 -
-
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