reset FORD GALAXY 2006 Service User Guide

the\fPCV\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\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
Pinpoint Te\bt\b
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

PCV\foil\fsep\br\btor\f
Electric\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\fsmokeEGR\fv\blve.\f
*Using\fthe\fWDS,\fCHECK\fthe\fPCM\fc\blibr\btion.\fIf\fnecess\bry\f
UPDATE\fthe\fPCM\fc\blibr\btion\fto\fthe\fl\btest\flevel.\fUsing\fthe\f
WDS,\fTOOLBOX/POWERTRAIN/SERVICE\fFUNCTIONS/RESET\f
KAM,\fRESET\fthe\fEGR\fv\blve.\fC\brry\fout\f\b\fro\bd\ftest,\fif\fthe\f
concern\fpersists\fGO\fto\fPinpoint\fTest\f A.\f\f
*
Excessive\f
cr\bnkc\bse\f
pressureBlocked\for\f
d\bm\bged\fPCV\f
hose(s).\f Blocked\fPCV\f
oil\fsep\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(303-01F\fEngine\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\fTesting).\f
*
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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 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\fins t
\bll\btion\fdet\bils.\f
In\btallation
Worldwide\fDi\bgnostic\fSystem\f(WDS) 1. Remove\fthe\fEGR\fv\blve\ftube.\fRefer\fto:\f Exh\bust\fM\bnifold\fto\fExh\bust\fG\bs\f
Re c

ircul\btion\f(EGR)\fV\blve\fTube \f(303-08D\fEngine\f
Emi

ssion\fControl\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\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. NOTE:\fThe\fg\bsket\fis\fto\fbe\freused\funless\f
d\b

m\bged.\f
1. Torque:\b 1
0\fNm\f
2. Torque:\b 8\fNm
\f
3. Torque:\b 5\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. Using\fthe\fWDS,\f TOOLBOX/POWERTRAIN/SERVICE\f
FUNCTIONS/RESET\fKAM,\freset\fthe\fEGR\fv\blve.\f
Genera\f\bEquipment:\b Worldwide\fDi\bgnostic\f
Sys

tem\f(WDS) \f
\f\f
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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\f
Electric\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
*
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On\fvehicles\fwith\f\buto\fst\brt/stop\ffunction,\finform\btion\fis\frequired\f\bbout\fwhether\f\b\fge\br\fis\f
eng\bged\for\fthe\ftr\bnsmission\fis\fin\fneutr\bl.\fThe\fneutr\bl\fposition\fsensor\fis\floc\bted\fon\fthe\f
tr\bnsmission\fhousing\ffor\fthis\fpurpose.\fThis\fis\fconnected\fto\fthe\fshift\flink\bge\fby\f\bn\f\bddition\bl\f
link\bge\fon\fthe\ftr\bnsmission.\f
The\fneutr\bl\fposition\fsensor\fis\f\b\fH\bll\fsensor\f\bnd\fis\fsupplied\fwith\f5\fVolt\fby\fthe\fPCM.\fThe\f
sign\bl\fvolt\bge\fv\bries\fbetween\f0.5\f\bnd\f5\fVolt\fwhen\foper\bting\fthe\flink\bge\f\bnd\fis\fmonitored\f
by\fthe\fPCM.\f
A\ffixed\fvolt\bge\fv\blue\fis\fstored\fin\fthe\fPCM\ffor\fe\bch\fge\br.\fAll\fv\blues\flying\fbetween\fthose\ffor\f
the\findividu\bl\fge\brs\f\bre\fstored\f\bs\fv\blues\ffor\fthe\fneutr\bl\fposition.\fThe\fPCM\ftherefore\f\blw\bys\f
detects\fwhether\for\fnot\f\b\fge\br\fis\feng\bged.\f
After\frepl\bcing\fthe\fsensor,\fthe\fv\blue\ffrom\fthe\fold\fsensor\fis\freset\fin\fthe\fPCM\fusing\fIDS.\fThe\f
vehicle\fmust\fthen\fbe\fdriven\f\b\fcert\bin\fdist\bnce\fso\fth\bt\fthe\fPCM\fc\bn\fle\brn\fthe\fnew\fv\blues\ffor\f
the\frelev\bnt\fge\brs\f\bnd\fneutr\bl\fpositions.\f
To\fdo\fthis,\fthe\fvehicle\fmust\fbe\fdriven\f\b\ftot\bl\fof\f5\ftimes\ffor\f10\fseconds\fe\bch,\f\bltern\btely\fin\f
3rd\f\bnd\f4th\fge\br\fwith\flow\f\bcceler\btion.\f
NOTE:\fIf\f\b\ff\bult\foccurs\fon\fthe\fneutr\bl\fposition\fsensor
\fwhen\fthe\fengine\fis\fst\btion\bry,\fthe\f
vehicle\fc\bn\fstill\fbe\fst\brted\fwith\fthe\fignition\fkey.\fIn\fthis\fc\bse,\f\b\fcorresponding\fDTC\fis\fset\f
in\fthe\fPCM.\f

no\fsign\bl\f\f

defective\fsign\bl\f
\f
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Installation\b
NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\finst\blling\f\b\fne
w\fcomponent.\f
Material\b
Gre
\bse\fKS-PS\f(SA-M1C9107-A\f/\fYS5J-
M1C
9107-AA) \f
Tor

\fue\b 48\fNm
\f
6. Co\bt\fthe\fstuds\fwith\fgre\bse.\f Material\b Gre\bse\fKS-PS\f(SA-M1C9107-A\f/\fYS5J-
M1C

9107-AA) \f
To r

\fue\b 48\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. C\brry\fout\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\f Reset\fthe\fDiesel\fP\brticul\bte\fFilter\fLe\brned\fV\blues\f
service\ffunction.\f
General E\fuipment\b Ford\fdi\bgnostic\fequipment \f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratorq-TDCi\b
(85kW/115PS)\b-\bDW/2.0L\bDuratorq-TDCi\b
(100kW/136PS)\b-\bDW/2.0L\bDuratorq-
TDCi\b(103kW/140PS)\b-\bDW,\bE\fission\b
Require\fents:\bStage\bIV\b-\bDiesel\b
Particulate\bFilter\b(DPF)\bDifferential\b
Pressure\bSensor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
General\bEquip\fent\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b
Ford\fdi\bgnostic\fequipment 1. Remove\fthe\ffront\fleft-h\bnd\fwheel\f\bnd\ftire.\fRefer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Ti r

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f\f 3.Torque:\b 5\fNm
\f
4. Torque:\b 5\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. C\brry\fout\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\f Reset\fthe\fDiesel\fP\brticul\bte\fFilter\fDifferenti\bl\f
Pressure\fSensor\fLe\brned\fV\blues\fservice\ffunction.
\f
Genera\f\bEquipment:\b Ford\fdi\bgnostic\fequipment \f
\f\f
\f\f
\f\f
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Installation\b6. Co\bt\fthe\fstuds\fwith\fgre\bse.\f
Mat

erial\b Gre\bse\fKS-PS\f(SA-M1C9107-A\f/\fYS5J-
M1C

9107-AA) \f
To r

\fue\b 48\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. C\brry\fout\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\f Reset\fthe\fDiesel\fP\brticul\bte\fFilter\fLe\brned\fV\blues\f
service\ffunction.\f
General E\fuipment\b Ford\fdi\bgnostic\fequipment \f
\f\f
\f\f
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Exhaust\bSyste\f\b-\b2.2L\bDuratorq-TDCi\b
(129kW/175PS)\b-\bDW\b-\bDiesel\bParticulate\b
Filter\b(DPF)\bDifferential\bPressure\bSensor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Re\foval\band\bInstallation\b
General\bEquip\fent\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation\b
Ford\fdi\bgnostic\fequipment 1. Remove\fthe\ffront\fleft-h\bnd\fwheel\f\bnd\ftire.\fRefer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Ti r

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f\f 3.Torque:\b 5\fNm
\f
4. Torque:\b 5\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
2. C\brry\fout\fthe\fpowertr\bin\fcontrol\fmodule\f(PCM)\f Reset\fthe\fDiesel\fP\brticul\bte\fFilter\fDifferenti\bl\f
Pressure\fSensor\fLe\brned\fV\blues\fservice\ffunction.
\f
Genera\f\bEquipment:\b Ford\fdi\bgnostic\fequipment \f
\f\f
\f\f
\f\f
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Instrum\bnt Clust\br \f Instrum\bnt Clust\brS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
D\bscription and Op\bration
The\finstrument\fcluster\fis\fp\brt\fof\fthe\fcentr\bl\fvehicle\fconfigur\btion\f\bnd\fs\bves\f\b\fcopy\fof\fthe\f
co

nfigur\btion\fd\bt\b\fstored\fin\fthe\fGEM.\fIt\f\bcts\f\bs\f\b\fb\bck-up\fcopy\fin\fthe\fevent\fth\bt\fthe\fGEM\f
must\fbe\frenewed.\f
After\fch\bnging\fthe\finstrument\fcluster,\fthe\fcurrent\fmile\bge\fof\fthe\fvehicle\fmust\fbe\fentered\f
using\fthe\fFord\fdi\bgnostic\funit.\f
Is\fit\fpossible\fto\freset\fthe\fmile\bge\fto\fzero\fon\fnew\fvehicles.\fThe\ffollowing\fconditions\f\bpply:\f

the\f20\fkilometer\f(mile)\flimit\fmust\fnot\fbe\fexceeded,\f\f

under\f20\fkilometers\f(miles),\fthe\fmile\bge\fc\bn\fbe\freset\fto\fzero\f\b\fm\bximum\fof\fthree\ftimes.\f
Ho

wever,\fresetting\fis\fonly\fpossible\fup\fto\f\b\ftot\bl\fof\f50\fkilometers.\f
For\fthis\fpurpose,\fthe\fconfirm\btion\fbutton\fon\fthe\fsteering\fwheel\fmust\fbe\fpressed\ffor\flonger\f
th
\bn\f7\fseconds.\f
The\finstrument\fcluster\fc\bn\fbe\fdi\bgnosed\fusing\fIDS.\f
V\bhicl\bs with low s\bri\bs instrum\bnt clust\br
\f\f
D\bscription
Glow\fplug\findic\btor\f
Speed\fcontrol\findic\btor\f
Ge\br\fch\bnge\findic\btor\f(ge\br\fch\bnge\frecommend\btion)\f
Air\fb\bg\fw\brning\findic\btor\f
Left-h\bnd\fturn\fsign\bl\findic\btor\f
Cool\bnt\ftemper\bture\fg\buge\f
Inform\btion\f\bnd\fmess\bge\fcenter\fdispl\by\f/\f\bl\brm\fsystem\fen\bbled\f
(when\fignition\foff)\f
Fuel\fLevel\fG\buge\f
Right-h\bnd\fturn\fsign\bl\findic\btor\f
It\bm 1
2
3
4
5
6
7
8
9
\f
Part Numb\br -
-
-
-
-
-
-
-
-
-
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Warning \bevice\f - Oil Change Indicator
Re\fetS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General Procedure\f
1. Close\f\bll\fdoors.\f
2. T
urn\fthe\fignition\fkey\fto\fposition\fII.\f
3. Simult\bneously\fpress\fthe\f\bcceler\btor\fped\bl\f\bnd\f the\fbr\bke\fped\bl\f\bnd\fhold\ffor\f\b\fminimum\fof\f15\f
seconds.\f
4.
Press\fthe\f"OK"\fbutton\fof\fthe\fmultifuction\bl\fswitch\f
\bnd\fthe\foil\fch\bnge\freminder\findic\btor\fwill\fturn\f
off.\fThis\fconfirms\fth\bt\fthe\freset\fprocedure\fh\bs\f
been\fcorrectly\fcompleted.\f
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