lock 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 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
*
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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
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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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Page 1792 of 4402
powerblocked.\f\b\fnew\f\bir\fcle\bner\felement\f\bs\fnecess\bry.\f
Ch\brge\f\bir\fcooler\f
pipe(s).\f
*INSPECT\fthe\fch\brge\f\bir\fcooler\fpipes\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fch\brge\f\bir\fcooler\fpipe(s)\f\bs\fnecess\bry.\f
*
Ch\brge\f\bir\fcooler\f
blocked.\f
*INSPECT\fthe\fch\brge\f\bir\fcooler\ffor\fblock\bge.\fINSTALL\f\b\f
new\fch\brge\f\bir\fcooler\f\bs\fnecess\bry.\f\f
REFER\fto:\f
Ch\brge\fAir\fCooler \f(303-12F\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Fuel\fch\brging\f\bnd\f
controls\f
*REFER\fto:\f
Fuel\fCh\brging\f\bnd\fControls\f(303-04E\fFuel\f
Ch\br
ging\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\fRequirements:\fSt\bge\f
IV,\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
*
Стр. 2 из
2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G953978&gui...procarmanuals.com
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Page 1806 of 4402
DLC\f(d\bt\b\flink\fconnector)\f
Medium\fspeed\fCAN\f
GEM\f(generic\felectronic\fmodule) \f
PCM\f(powertr\bin\fcontrol\fmodule) \f
injectors\f
HO2S\f(he\bted\foxygen\fsensor)\f
CKP\f(cr\bnksh\bft\fposition)\f
ECT\f(engine\fcool\bnt\ftemper\bture) \f
St\brter\fRel\by\f
Ignition\flock\f
PCM\frel\by\f
B\bttery\f
Instrument\fcluster\f
Fuel\fpump\fdriver\fmodule\f
\fomme\bts:
Of\fwhich\fthe\ffollowing\f\bre\frelev\bnt\fhere:\fFlo\bt\f\brm,\fresistor\fbo\brd\f
Refer\fto:\f Fuel\fT\bnk\f\bnd\fLines\f-\f2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW
/145PS)\f-\fMI4,\fVehicles\f
With:\fEth\bnol\fC\bp\bbility \f(310-01A\fFuel\fT\bnk\f\bnd\fLines\f-\f2.0L\fEcoBoost\fSCTi\f(14
9kW/203PS)\f-\f
MI4/2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4/2.3L\fDur\btec-HE\f(118kW/160PS)\f-\fMI4/2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5,\fDescription\f
\bnd\fOper\btion).\f
Instrument\fcluster\f
System Operatio\b
Fuel type determi\batio\b a\bd adaptatio\b
Th
e\fcruci\bl\ff\bctor\ffor\foptim\bl\f\bd\bpt\btion\fof\fthe\ffuel-\bir\fmixture\fis\fknowledge\fof\fthe\ffuel\f
composition\fin\fthe\ffuel\ft\bnk.\fTo\fdetermine\fthe\feth\bnol\fsh\bre\fin\fthe\ffuel,\fthe\f HO2S\fsign\bl\f
\bnd
\fthe\ffuel\flevel\fsensor\f\bre\fused.\fA\fcorresponding\f\blgorithm\fin\fthe\f PCM\fc\blcul\btes\fthe\ffuel\f
co m
position\ffrom\fthese.\f
The\ffollowing\fprerequisites\fmust\fbe\ffulfilled\ffor\ffuel\ftype\fdetermin\btion:\f
The\ffuel\flevel\fmust\fbe\fincre\bsed\fby\f\bt\fle\bst\f10\fliters\fif\fthe\ffuel\flevel\fsensor\fh\bs\freported\f
th
\bt\fthe\ffuel\ft\bnk\fis\fempty.\f\f
The\ffuel\flevel\fmust\fbe\fincre\bsed\fby\f\bt\fle\bst\f5\fliters\fif\fthe\ffuel\ft\bnk\fis\fp\brti\blly\ffull.\f\f
Approxim\btely\f0.1\fliters\fof\ffuel\fmust\fh\bve\fbeen\fconsumed\fsince\frefueling\f\f
Engine\fm\bn\bgement\fis\fworking\fin\f\b\fclosed\floop\f(L\bmbd\b\fcontrol\fis\f\bctive).\fThis\frequires\f
\bn\f
engine\ftemper\bture\fof\f\bpproxim\btely\f30\fto\f40°C\f\f
The\fengine\flo\bd\fis\fin\fthe\fr\bnge\fbetween\fidling\f\bnd\ffull\flo\bd\f(provided\fno\ffuel\fenrichment\f
is
\fc\brried\fout\fto\fprotect\fthe\fc\bt\blyst)\f\f
No\ferror\fcodes\f\bre\fs\bved\fin\fthe\f PC
M\f
The\ffollowing\fevents\fc\bn\ftrigger\f\b\ffuel\ftype\fdetermin\btion:\f
\b\fsufficient\fincre\bse\fin\fthe\ffuel\flevel\fin\fthe\ffuel\ft\bnk\f\f
\bn\fempty\ffuel\ft\bnk\for\fvery\flow\ffuel\flevel\f\bfter\fprolonged\fst\bndstill\fof\fthe\fvehicle\for\f
st
\brting\fof\fthe\fengine\f\f
progr\bmming\fof\fthe\f PC
M\f
As\fthe\ffuel\flevel\frises,\fthe\fflo\bt\f\brm\fof\fthe\ffuel\flevel\fsensor\frises\f\bnd\fch\bnges\fthe\fsensing\f
p o
sition\fon\fthe\fresist\bnce\ftr\bck\fof\fthe\fresistor\fbo\brd.\fThe\fresistor\fbo\brd\ftr\bnsfers\fthe\f
resulting\fdrop\fin\fvolt\bge\fto\fthe\f GEM\fvi\b\fdirect\fwiring.\fThe\f GEM\fsends\fthis\fv\blue\fto\fthe\f CAN\f
vi \b
\f PCM .\fWhen\fthe\f\bbove\fconditions\ffor\ffuel\ftype\fdetermin\btio
n\fh\bve\fbeen\fmet,\fthe\fPCM\f
2
3
4
5
6
7
8
9
1 0
1
1
12
13
14
15
16
Стр. 2 из 3
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Page 1813 of 4402
Electro\bic E\bgi\be \fo\btrols - 2.0L Duratec-
HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4 -
\fra\bkshaft Positio\b (\fKP) Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Special Tool(s)
Removal
I\b
stallatio\b
303-1390\f
Alignment\fTool,\fCr\bnksh\bft\fPosition\fSensor
\f
1. \f\f 1. CAUTION:\fOnly\frot\bte\fthe\f
cr
\bnksh\bft\fclockwise.\f
NOTE:\fM\bke\fsure\fth\bt\fthe\finst\bll\btion\f
m\brks\f\bre\f\bligned.\f
2. Bolt\fM6x18\fmm\f
1. Special\bTool(\f):\b 303-1390\f
Tor
que:\b 7\fNm
\f
2. \f
\f
\f
\f\f
Стр. 1 из 2
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