check engine FORD S-MAX 2006 Service Repair Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 1720 of 4402
Is\fthe\fvolt\bge\fgre\bter\fth\bn\f10\fvolts?\f
Yes\bGO\fto\fB4.\f\f
No\b I
NSTALL\f\b\fnew\fBJB.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
B4:\bCHECK\bCIRCUIT\bCDC35\b(BU/WH)\bFOR\bCONTINUITY
Ignition\fswitch\fin\fposition\f0.\f1\b
Me\bsure\fthe\fresist\bnce\fbetween\fthe\fBJB\fst\brter\f
rel\by\fR1\fconnector\fpin\f5\f\bnd\fthe\fst\brter\fmotor\f
solenoid\fC1DC35-B\fpin\f1,\fcircuit\fCDC35B\f(BU/WH).\f2\b
Is\fthe\fresist\bnce\fless\fth\bn\f1\fohm?\f
Yes\b INSTALL\f\b\fnew\fst\brter\frel\by.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\fIf\fthe\fconcern\fpersists,\fINSTALL\f
\b\fnew\fBJB.\fTEST\fthe\fsystem\ffor\fcorrect\foper\btion.\f
No\b REPAIR\fcircuit\fCDC35A\f(BU/WH)\for\fcircuit\fCDC35B\f
(BU/WH)\f\bs\fnecess\bry.\fTEST\fthe\fsystem\ffor\fcorrect\f
oper\btion.\f
PINPOINT\bTEST\bC\b:\bTHE\bENGINE\bCRANKS\bSLOWLY\b
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
C1:\bCHECK\bTHE\bBATTERY\bVOLTAGE\bAND\bCONDITION
CHECK\fthe\fb\bttery\fusing\f\b\fb\bttery\ftester.\f1\b
Is\fthe\fb\bttery\fvolt\bge\f\bnd\fcondition\fOK?\f
Yes\bGO\fto\fC2 .\f\f
No\b
C
HARGE\for\finst\bll\f\b\fnew\fb\bttery\f\bs\frequired.\f
CHECK\fthe\fch\brging\fsystem\fusing\fWDS.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
C2:\bCHECK\bCIRCUIT\bSBF01A\b(RD)\bFOR\bVOLTAGE\bDROP
Ignition\fswitch\fin\fposition\fIII.\f1\b
Me\bsure\fthe\fvolt\bge\fbetween\fst\brter\fmotor\f
solenoid\fC1DC35-A-1\fcircuit\fSBF01A\f(RD),\f
component\fside\f\bnd\fthe\fb\bttery\fpositive\ftermin\bl.\f2\b
\f\f
\f\f
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Page 1737 of 4402
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 1746 of 4402
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
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Page 1755 of 4402
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\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\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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Page 1756 of 4402
![FORD S-MAX 2006 Service Repair Manual 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\](/img/11/56999/w960_56999-1755.png "FORD S-MAX 2006 Service Repair Manual 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\")
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\fWDS.\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\fWDS,\fDATALOGGER,\fset\fthe\fp\br\bmeters\fDPFEGR,\fRPM,\fEGRDC#.\f2
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(303-08D\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,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\fInst\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(303-08D\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,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\fInst\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(303-08D\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,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\fInst\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
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Page 1757 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\](/img/11/56999/w960_56999-1756.png "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\")
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\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\f
Ye\b
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\fthe\fconcern\f
persists,\f\f
REFER\fto:\f Engine\f(303-01F\fEngine\f-\f2.0L\fDur\btorq-
TDC
i\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:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
No
CLEAN\fthe\fPCV\foil\fsep\br\btor\f\bnd\fPCV\fv\blve\f\bssembly\f
or\fINSTALL\f\b\fnew\fint\bke\fm\bnifold\f\bs\fnecess\bry.\f\f
REFER\fto:\f Int\bke\fM\bnifold \f(303-01F\fEngine\f-\f2.0L\f
Dur
\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:\fSt\bge\f
IV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
\f\f
\f\f
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Page 1764 of 4402
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
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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\](/img/11/56999/w960_56999-1764.png "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\](/img/11/56999/w960_56999-1765.png "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\")
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\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\f
Ye\b
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\fIf\fthe\fconcern\f
persists,\f\f
REFER\fto:\f Engine\f(303-01G\fEngine\f-\f2.2L\fDur\btorq-
TDC
i\f(129kW/175PS)\f-\fDW,\fDi\bgnosis\f\bnd\fTesting).
\f
No CLEAN\fthe\fcr\bnkc\bse\fvent\foil\fsep\br\btor\f\bnd\fPCV\f
v\blve\f\bssembly\for\fINSTALL\f\b\fnew\fint\bke\fm\bnifold\f\bs\f
necess\bry.\f\f
REFER\fto:\f Int\bke\fM\bnifold \f(303-01G\fEngine\f-\f2.2L\f
Dur
\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
\f\f
\f\f
Стр. 4 из
4
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Page 1791 of 4402
Intake \bir Di\ftribution and Filtering - 2.2L
Duratorq-TDCi (129kW/175PS) - DW -
Intake \bir Di\ftribution and Filtering
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
In\fpection and Verification
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\fual In\fpection Chart
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 Chart
Mechanica\bE\bectrica\b
Air\fcle\bner\felement\f\f
Air\fcle\bner\fint\bke\fhose\f\f
Air\fcle\bner\foutlet\fhose\f\f
Ch\brge\f\bir\fcooler\f\f
Ch\brge\f\bir\fcooler\fint\bke\fhose\f\f
Ch\brge\f\bir\fcooler\foutlet\fhose\fM\bss\f\bir\fflow\f(MAF)\fsensor\f\f
M\bnifold\f\bbsolute\fpressure\f(MAP)\fsensor\f\f
Electric\bl\fconnector(s)\f
\fymptomPossib\be \fourcesAction
Excessive\f
int\bke\f\bir\f
noiseDet\bched\f\bir\fcle\bner\f
hose(s).\f Det\bched\f
turboch\brger\fhose(s).
\f
Det\bched\fch\brge\f\bir\f
cooler\fhose(s).\f
*
*
*
CHECK\fthe\fhose(s)\ffor\fsecurity\f\bnd\fle\bks\fto\f
\btmosphere.\fINSTALL\fnew\fint\bke\f\bir\fcomponents\f\bs\f
necess\bry.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Oil\fin\fthe\f\bir\f
int\bke\f
system
Blocked\for\fd\bm\bged\f
positive\fcr\bnkc\bse\f
ventil\btion\f(PCV)\f
v\blve.\f
Blocked\for\fd\bm\bged\f
PCV\fpipe(s)/hose(s).\f Blocked\for\fd\bm\bged\f
cr\bnkc\bse\fvent\foil\f
sep\br\btor.\f
*
*
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08E\fEngine\f
Emi
ssion\fControl\f-\f2.2L\fDur\btorq-
TDCi\f(129kW/175PS)\f
-\fDW,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger.\f
*REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\fTurboch\brger\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:\fSt\bge\f
IV,\fDi\bgnosis\f\bnd\fTesting).\f
*
W\bter\fin\fthe\f
\bir\fcle\bner
Air\fint\bke\fpipe\fspl\bsh\f
shield.\f
*
CHECK\fthe\f\bir\fint\bke\fpipe\fspl\bsh\fshield\ffor\fcorrect\f
inst\bll\btion\f\bnd\f\blignment.\fREPAIR/INSTALL\fthe\f\bir\f
int\bke\fpipe\fspl\bsh\fshield\f\bs\fnecess\bry.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Blocked\f\bir\fcle\bner\f
dr\bin.\f
*CHECK\fthe\f\bir\fcle\bner\fdr\bin\ffor\fblock\bge.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
Engine\fl\bcks\fAir\fcle\bner\felement\f
*INSPECT\fthe\f\bir\fcle\bner\ffor\fsigns\fof\fblock\bge.\fINSTALL\f*
Стр. 1 из 2
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