ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Diagnosis and Testing|Removal and Installation > < Engine Emission Control

Focus 2004.75 (07.2004-)

Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel - Engine Emission Control Focus 2004.75 (07/2004-)
Diagnosis and Testing

General Equipment
Worldwide Diagnostic System (WDS)

Principles of Operation

Exhaust Gas Recirculation (EGR) System

To maintain the standards of low exhaust emission levels required by todays engines, the EGR system on this engine is fully electronically monitored and controlled.

The EGR valve is a proportional electric motor controlled directly by a duty-cycle signal from the powertrain control module (PCM). Integrated into the EGR valve is a valve position sensor. The signal from the EGR valve position sensor allows for the precise control of the timing and the quantity of exhaust gas to be recirculated. If the EGR valve becomes inoperative or fails to close completely, the PCM will raise a diagnostic trouble code (DTC) and the instrument cluster malfunction indicator lamp (MIL) will be illuminated. At the end of each drive cycle the PCM drives the EGR valve to the fully open and fully closed positions several times. This assists with cleaning the EGR valve.

If a new EGR valve is installed. The base setting (closed position) value must be configured to the PCM. This is initiated using WDS. If the base setting is not configured to the PCM, the setting from the previous EGR valve will be used and the control function of the EGR system will be incorrect.

The EGR system on vehicles with 110PS stage 4 + fuel additive and 90PS engines are fitted with a EGR cooler. The EGR cooler reduces the temperature of the exhaust gasses being returned to the intake system. By reducing the EGR temperature, the intake air charge density is not adversely affected, so maintaining the optimum fueling characteristics.

Positive Crankcase Ventilation (PCV)

 
Item
Part Number
Description
1
-
Engine crankcase pressure outlet.
2
-
Oil separator chamber.
3
-
PCV valve.

The PCV system consists of an oil separator chamber containing a PCV valve, connected to the air intake system with a hose. The oil separator chamber and PCV valve are an integral part of the engine valve cover.

Inspection and Verification

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

Visual Inspection Chart

Mechanical Electrical
  • EGR valve
  • EGR valve tube
  • EGR valve tube clamp
  • EGR cooler
  • EGR valve gasket
  • PCV hose
  • PCV valve
  • PCV oil separator
  • Electrical connector
  • Wiring harness
  • EGR 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 DTC Index Chart.
  1. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnosis.

Diagnostic Trouble Code (DTC) Index Chart

DTC Description Possible Source Action
P1412 MIL illuminated with reduced engine torque EGR valve REFER to Excessive exhaust black smoke in the Symptom Chart
P0404 MIL illuminated EGR valve REFER to Excessive exhaust black smoke in the Symptom Chart

Symptom Chart

Symptom Chart

Symptom Possible Sources Action
Excessive exhaust black smoke
*
EGR valve incorrect base setting.
*
EGR valve.
*
Using the WDS, CHECK the PCM calibration. If necessary UPDATE the PCM calibration to the latest level. Using the WDS, TOOLBOX/POWERTRAIN SERVICE FUNCTIONS/COMPONENT OR PARAMETER RESET/EGR RE-CALIBRATION, RESET the EGR valve. Carry out a road test, if the concern persists GO to Pinpoint Test A.
Excessive crankcase pressure
*
Blocked or damaged PCV hose(s).
*
Blocked PCV oil separator.
*
Blocked or damaged PCV valve.
*
GO to Pinpoint Test B.
*
Worn or damaged engine components.
*
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).

Pinpoint Tests

PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE EXHAUST GAS RECIRCULATION VALVE POSITION
1
Ignition switch in position III.
2
Using the WDS, DATALOGGER, set the parameters EGRDC#, RPM, EGRVP, DTC_CNT.
3
Set the DISPLAY function to a minimum of 30 seconds.
4
Set DATALOGGER to RECORD.
5
Ignition switch in position 0.

Does the EGRVP parameter change from a minimum value of 0% to a maximum value of 100% 10 times after the engine is switched off?
Yes
GO to A3.
No
RECORD the DTCs and DATALOGGER freeze frame data. INSTALL a new EGR valve.
REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
TEST the system for normal operation.
A2: CHECK THE EGR VALVE RESPONSE TO ENGINE RPM AND THROTTLE POSITION
1
Ignition switch in position III.
2
Set DATALOGGER to RECORD.
3
During the test observe the EGRDC# parameter in DATALOGGER. The following parameters should be tested.
  • EGRDC# shows 0% during engine speed increase and above 3,500 RPM.
  • EGRDC# shows approximately 20% to 30% open between 1,500 RPM and 2,500 RPM.
  • EGRDC# parameter moves rapidly in response to throttle position.

Are all of the tests completed within the parameters shown?
Yes
GO to A3.
No
RECORD the DTCs and DATALOGGER freeze frame data. INSTALL a new EGR valve.
REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
TEST the system for normal operation.
A3: CHECK EXHAUST GAS RECIRCULATION VALVE FOR DAMAGE
1
Remove the EGR valve tube.
REFER to: Exhaust Manifold to Exhaust Gas Recirculation (EGR) Valve Tube - VIN Plate Emission Level Code: S (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).

2
INSPECT the EGR valve and valve seat for damage.

Is the EGR valve undamaged and in the closed position?
Yes
To continue diagnostics,
REFER to: Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
No
INSTALL a new EGR valve.
REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08C Engine Emission Control - 1.6L Duratorq-TDCi (DV) Diesel, Removal and Installation).
TEST the system for normal operation.

PINPOINT TEST B : EXCESSIVE CRANKCASE PRESSURE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE POSITIVE CRANKCASE VENTILATION HOSE FOR BLOCKAGE

1
Remove the air cleaner outlet hose.
2
Inspect the PCV hose for blockage.

Is the PCV hose free from blockage?
Yes
GO to B2.
No
CLEAN or INSTALL a new PCV hose as necessary. TEST the system for normal operation. If the concern persists, GO to B2.
B2: CHECK THE POSITIVE CRANKCASE VENTILATION VALVE FOR DAMAGE.

1
Inspect the PCV valve for damage or blockage.

Is the PCV valve spring undamaged and the PCV valve free from blockage?
Yes
Test the system for normal operation. If the concern persists,
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No
CLEAN the PCV oil separator and PCV valve assembly or INSTALL a new engine valve cover as necessary. Test the system for normal operation.

Diagnosis and Testing|Removal and Installation > < Engine Emission Control