2006 FORD S-MAX Service Repair Manual

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Page 1761 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.0L Du\fato\fq- TDCi (85kW/115PS) - DW/2.0L Du\fato\fq- TDCi (100kW/136PS) - DW/2.0L Du\fato\fq- TDCi (103kW/140PS) - DW, Emi\b\bion Requi\fement\b: Stage IV - Exhau\bt$

Page 1762 of 4402

$FORD S-MAX 2006 Service Repair Manual In\btallation 4. Torque:\b 1 0\fNm\f 1. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcl\bmp\fis\finst\blled.\f NOTE:\fM\bke\fsure\fth\bt\fthe\fcl\bmp\fis\finst\blled\fto\fthe\f s\bme\forient\btion\f\bs\fwhen\$

Page 1763 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.2L Du\fato\fq- TDCi (129kW/175PS) - DW - Engine Emi\b\bion Cont\fol— S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagno\bi\b and Te\bting Gene\fal Equipment P\finc$

Engine Emi\b\bion Cont\fol - 2.2L Du\fato\fq-
TDCi (129kW/175PS) - DW - 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\bys\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.\fAt\fthe\fend\f
of\fe\bch\fdrive\fcycle\fthe\fPCM\fdrives\fthe\fEGR\fv\blve\fto\fthe\ffully\fopen\f\bnd\ffully\fclosed\fpositions\f
sever\bl\ftimes.\fThis\f\bssists\fwith\fcle\bning\fthe\fEGR\fv\blve.\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\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\fIf\fthe\fb\bse\fsetting\fis\fnot\fconfigured\fto\f
the\fPCM,\fthe\fsetting\ffrom\fthe\fprevious\fEGR\fv\blve\fwill\fbe\fused\f\bnd\fthe\fcontrol\ffunction\fof\f
the\fEGR\fsystem\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\ffuelling\f
ch\br\bcteristics.\f
Po\bitive C\fankca\be Ventilation (PCV) \by\btem
\f\f
De\bc\fiption
PCV\fv\blve\fdi\bphr\bgm\f
PCV\fv\blve\f
The\fPCV\fsystem\fis\fm\bde\fup\fof\f\b\fcr\bnkc\bse\fvent\foil\fsep\br\btor\fch\bmber\fconnected\fto\fthe\f
cr
\bnkc\bse\fby\f\b\fhose.\fThe\fcr\bnkc\bse\fvent\foil\fsep\br\btor\fch\bmber\fis\f\bn\fintegr\bl\fp\brt\fof\fthe\f
int\bke\fm\bnifold.\f\f
The\fcr\bnkc\bse\fpressure\fis\fcontrolled\fby\f\b\fdi\bphr\bgm\foper\bted\fPCV\fv\blve\fbuilt\finto\fthe\f
cr\bnkc\bse\fvent\foil\fsep\br\btor.\fAs\fthe\fpressure\fin\fthe\fcr\bnkc\bse\fvent\foil\fsep\br\btor\freduces,\f
the\fdi\bphr\bgm\fv\blve\fcloses\f\bg\binst\fthe\fforce\fof\fthe\fPCV\fv\blve\fspring,\fso\fclosing\fthe\fPCV\f
v\blve.\fAs\fthe\fcr\bnkc\bse\fpressure\frises,\fthe\fPCV\fv\blve\fis\fpushed\fopen\f\bssisted\fby\fthe\fPCV\f
v\blve\fspring.\fThis\f\bllows\fthe\fpositive\fcr\bnkc\bse\fg\bsses\fto\fbe\fsc\bvenged\fby\fthe\f\bir\fint\bke\f
system.\f
Ford\f\bpproved\fdi\bgnostic\ftool
Item 1
2 \f\f
Pa\ft Numbe\f
-
-
Стр. 1 из 4
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Page 1764 of 4402

$FORD S-MAX 2006 Service Repair Manual In\bpection and Ve\fification 1. 1. Verify\fthe\fcustomer\fconcern.\f 2 . 2. Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f V i\bual In\bpection Cha\ft 3.$

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\fDTC\fIndex\f
C
h\brt.\f
5. 5.
If\fno\fDTCs\frel\bted\fto\fthe\fconcern\f\bre\fretrieved,\fproceed\fto\fthe\fSymptom\fCh\brt\fto\f
c
ontinue\fdi\bgnosis.\f
Diagno\btic T\fouble Code (DTC) Index Cha\ft
Symptom Cha\ft
Mechanica\bE\bectrica\b
Exh\bust\fg\bs\frecircul\btion\f(EGR)\fv\blve\f\f
EGR\ftube\f\f
EGR\fcooler\f\f
EGR\ftube\fcl\bmp\f\f
G\bsket\f\f
PCV\fhose\f\f
Cr\bnkc\bse\fvent\foil\fsep\br\btor\fElectric\bl\fconnector\f\f
Wiring\fh\brness\f
\fTC\fescription
Possib\be
Source
Action
P1412MIL\fillumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
P0404MIL\fillumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
P1335Powertr\bin\fw\brning\findic\btor\f illumin\btedEGR\fv\blveREFER\fto\fExcessive\fexh\bust\fbl\bck\fsmoke\fin\f
the\fSymptom\fCh\brt
SymptomPossib\be
SourcesAction
Excessive\f
exh\bust\f
bl\bck\f
smokeEGR\fv\blve.\f
*Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fCHECK\fthe\fPCM\f
c\blibr\btion.\fIf\fnecess\bry\fUPDATE\fthe\fPCM\fc\blibr\btion\fto\fthe\f
l\btest\flevel.\fUsing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\f
TOOLBOX/POWERTRAIN\fSERVICE\fFUNCTIONS/COMPONENT\f
OR\fPARAMETER\fRESET/EGR\fRE-CALIBRATION,\fRESET\fthe\fEGR\f
v\blve.\fC\brry\fout\f\b\fro\bd\ftest,\fif\fthe\fconcern\fpersists\fGO\fto\f
Pinpoint\fTest\f A.\f\f
*
Excessive\f
cr\bnkc\bse\f
pressureBlocked\for\f
d\bm\bged\fPCV\f
hose(s).\f
Blocked\f
cr\bnkc\bse\f
vent\foil\f
sep\br\btor.\f
*
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Worn\for\f
d\bm\bged\f
engine\f
components.\f
*REFER\fto:\f
Engine\f(303-01G\fEngine\f-\f2.2L\fDur\btorq-TDCi\f
(12
9kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
*
Стр. 2 из
4
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Page 1765 of 4402

$FORD S-MAX 2006 Service Repair Manual Pinpoint Te\bt\b PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS A1: CHECK THE EXHAUST GAS RECIRCULATION VALVE POSITION NOTE:\fAllow\fthe\fengine\fto\fidle\$

Pinpoint Te\bt\b
PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE
TEST
CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: CHECK THE EXHAUST GAS RECIRCULATION VALVE POSITION
NOTE:\fAllow\fthe\fengine\fto\fidle\ffor\f\b\fminimum\fof\ffour\fminutes\fbefore\fc\brrying\fout\fthe\f
system\fchecks\fusing\fthe\fFord\f\bpproved\fdi\bgnostic\ftool.\f
NOTE:\fAfter\fthe\fengine\fis\fswitched\foff,\fthe\fEGR\fv\blve\fwill\f\bttempt\fthe\fcle\bning\fcycle\fup\f
to\f\b\fm\bximum\fof\f18\ftimes.\fIf\f18\fcycles\f\bre\fseen\fduring\fthe\ftest\fthe\fEGR\fv\blve\fis\fsuspect\f
\bnd\fshould\fbe\fch\bnged.\f
Ignition\fswitch\fin\fposition\fIII.\f1
Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\fDATALOGGER,\fset\fthe\fp\br\bmeters\f
DPFEGR,\fRPM,\fEGRDC#.\f
2
Set\fDATALOGGER\fto\fRECORD.\f3
Ignition\fswitch\fin\fposition\f0.\f4
Does\fthe\fDPFEGR\f0\fto\f5\fvolt\fp\br\bmeter\fch\bnge\ffrom\f\b\fminimum\f\bpproxim\bte\f
v\blue\fof\f0.9\fvolts\fto\f\b\fm\bximum\f\bpproxim\bte\fv\blue\fof\f4.2\fvolts\ffor\f\b\ftot\bl\fof\f6\f
cycles?\f
Ye\b GO\fto\fA2.\f\f
No R

ECORD\fthe\fDTCs\f\bnd\fDATALOGGER\ffreeze\ffr\bme\fd\bt\b.\fINSTALL\f\b\fnew\f
EGR\fv\blve.\f\f
REFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-08E\fEngine\f
Emi

ssion\fControl\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A2: CHECK THE EXHAUST GAS RECIRCULATION VALVE FOR DAMAGE
Remove\fthe\fEGR\fv\blve.\f\f
REFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-08E\fEngine\f
Emi

ssion\fControl\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
1
INSPECT\fthe\fEGR\fv\blve\f\bnd\fv\blve\fse\bt\ffor\fd\bm\bge\for\fexcessive\fc\brbon\f
build\fup.\fREMOVE\fthe\fpl\bstic\fcover\fon\fthe\fEGR\fv\blve\f\bnd\fcheck\fthe\fEGR\f
v\blve\fc\bm\f\bctu\btor\ffor\ffree\fmovement.\f2
Is\fthe\fEGR\fv\blve\fund\bm\bged\f\bnd\fin\fthe\fclosed\fposition\f\bnd\fthe\fEGR\fv\blve\fc\bm\f
\bctu\btor\ffree\fto\fmove?\f
Ye\b To\fcontinue\fdi\bgnostics,\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04E\fFuel\fCh\brging\f\bnd\fControls\f
-\f2

.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\fTesting).\f
No INSTALL\f\b\fnew\fEGR\fv\blve.\f\f
REFER\fto:\f Exh\bust\fG\bs\fRecircul\btion\f(EGR)\fV\blve \f(303-08E\fEngine\f
Emi

ssion\fControl\f-\f2.2L\fDur\btorq-TDCi\f(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : EXCESSIVE CRANKCASE PRESSURE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
B1: CHECK THE PCV HOSE FOR BLOCKAGE
Remove\fthe\fPCV\fhose.\f1
Стр. 3 из 4
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Page 1766 of 4402

$FORD S-MAX 2006 Service Repair Manual Inspect\fthe\fPCV\fhose\ffor\fblock\bge.\f2 Is\fthe\fPCV\fhose\ffree\ffrom\fblock\bge?\f Ye\b GO\fto\fB2.\f\f No C LEAN\for\fINSTALL\f\b\fnew\fPCV\fhose\f\bs\fnecess\bry.\f TEST\fthe\fsystem\ffor\$

Page 1767 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.2L Du\fato\fq- TDCi (129kW/175PS) - DW - Exhau\bt Ga\b Reci\fculation (EGR) Valve S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal and In\btallation Removal In \$

Page 1768 of 4402

$FORD S-MAX 2006 Service Repair Manual Engine Emi\b\bion Cont\fol - 2.2L Du\fato\fq- TDCi (129kW/175PS) - DW - Exhau\bt Ga\b Reci\fculation (EGR) Coole\f S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Removal and In\btallation Gene\fal Equ$

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