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Engine Emission Control - Vehicles With: Electronic Exhaust Gas Recirculation (EGR) Valve > < Engine Emission Control

Fiesta 2002.25 (11.2001-)

Engine Emission Control - 1.4L Duratorq-TDCi (DV) Diesel - Engine Emission Control—Vehicles With: Vacuum Exhaust Gas Recirculation (EGR) Valve Fiesta 2002.25 (11/2001-)
Diagnosis and Testing

Special Tool(s)

Hand Vacuum/Pressure Pump

416-D001 (23-036A)

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical
Exhaust gas recirculation (EGR) valve
EGR tube
EGR tube clamps
Gaskets/seals
EGR vacuum regulator valve
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Excessive exhaust black smoke
*
EGR valve.
*
EGR vacuum regulator valve.
*
GO to Pinpoint Test A. .

Pinpoint Tests

PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK VACUUM TO THE EGR VALVE

1
Disconnect the vacuum line from the EGR valve.
2
Connect the special tool to the disconnected vacuum line.
3
START the engine.

4
Using the special tool, measure the vacuum at the EGR vacuum line.

With the engine at idle, is no vacuum indicated on the vacuum gauge?
Yes
GO to A2. .
No
Using WDS, CHECK the OPEN and CLOSE input signal to the EGR vacuum regulator valve. If the result is CLOSE, INSTALL a new vacuum regulator valve. TEST the system for normal operation. If the result is OPEN continue the diagnostic with WDS.
A2: CHECK THE EGR VALVE CONTROL ROD
1
Connect the special tool to the EGR valve.

2
Using the special tool, apply a vacuum to the EGR valve.
3
Release the vacuum and observe the movement of the EGR valve control rod.

Does the EGR valve open and return to the fully closed position?
Yes
GO to A3. .
No
INSTALL a new EGR valve.
REFER to Exhaust Gas Recirculation (EGR) Valve - in this section.
TEST the system for normal operation.
A3: CHECK THE EGR VALVE
1
Remove the EGR valve.
REFER to Exhaust Gas Recirculation (EGR) Valve - in this section.
2
Inspect the EGR valve for damage.

Is the EGR valve OK?
Yes
REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls - Turbocharger.
No
INSTALL a new EGR valve.
REFER to Exhaust Gas Recirculation (EGR) Valve - in this section.
TEST the system for normal operation.

Engine Emission Control - Vehicles With: Electronic Exhaust Gas Recirculation (EGR) Valve > < Engine Emission Control