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

Mondeo 2007.5 (02.2007-)

Engine Emission Control - 1.8L Duratorq-TDCi (Lynx) Diesel - Engine Emission Control Mondeo 2007.5 (02/2007-)
Diagnosis and Testing

General Equipment
Ford approved diagnostic tool

Principles of Operation

Exhaust Gas Recirculation (EGR) system

To maintain the standards of low exhaust emission levels required, the EGR system is fully electronically 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.

The EGR system is fitted with an 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 fuelling characteristics.

Positive Crankcase Ventilation (PCV) system

 
Item
Part Number
Description
1
-
PCV valve cover
2
-
PCV valve diaphragm
3
-
PCV valve bush
4
-
PCV valve spring
5
-
Valve cover

The PCV system consists of a crankcase vent oil separator connected to the crankcase and valve cover by hoses.

The crankcase pressure is controlled by a diaphragm operated PCV valve built into the valve cover and cannot be removed. As the pressure in the crankcase vent oil separator reduces, the diaphragm valve closes against the force of the PCV valve spring, so closing the PCV valve. As the crankcase pressure rises, the PCV valve is pushed open assisted by the PCV valve spring. This allows the positive crankcase gasses to be scavenged by the air intake system.

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 cooler
  • Gasket(s)
  • PCV hoses
  • Crankcase vent oil separator
  • Electrical connector
  • Wiring harness
  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 diagnostic trouble code (DTC) Index Chart.

Diagnostic Trouble Code (DTC) Index Chart

DTC Description/Condition Possible Source Action
P1402 EGR metering orifice restricted EGR valve stuck closed or leaking GO to Pinpoint Test A.
  1. If no DTCs are retrieved, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
Excessive exhaust black smoke
*
EGR valve.
*
GO to Pinpoint Test A.
Excessive crankcase pressure
*
Blocked or damaged PCV hose(s).
*
Blocked crankcase vent oil separator.
*
GO to Pinpoint Test B.
*
Worn or damaged engine components.
*
REFER to: Engine (303-01, Diagnosis and Testing).

Pinpoint Tests

PINPOINT TEST A : EXCESSIVE EXHAUST BLACK SMOKE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: CHECK THE EGR VALVE
1
Using the WDS, CHECK for DTC P1402.

Is DTC P1402 retrieved?
Yes
INSTALL a new EGR valve.
REFER to: Exhaust Gas Recirculation (EGR) Valve (303-08, Removal and Installation).
TEST the system for normal operation.
No
Continue the diagnostic using the Ford approved diagnostic tool.

PINPOINT TEST B : EXCESSIVE CRANKCASE PRESSURE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE PCV HOSES FOR BLOCKAGE

1
Remove the PCV hoses.
2
Inspect the PCV hoses and connections for blockage.

Are the PCV hoses and connections free from blockage?
Yes
INSTALL a new valve cover.
REFER to: Valve Cover (303-01, Removal and Installation).
No
CLEAN or INSTALL new PCV hoses as necessary. TEST the system for normal operation. If the concern persists, CLEAN or INSTALL a new crankcase vent oil separator as necessary. TEST the system for normal operation.

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