2009 Ford C-Max 2.0 TDCi (136) Zetec DPF – Workshop Service & Repair Manual

1. Check for Warnings: If your dashboard displays a DPF warning light, it indicates that the filter needs attention.
2. Perform a Regeneration: Drive at a consistent speed of at least 40 mph for 15-30 minutes to allow the filter to regenerate by burning off accumulated soot.
3. Manual Regeneration: If the automatic regeneration doesn't work, a manual or forced regeneration may be required. Consult a professional mechanic for this procedure.
4. Use DPF Cleaner: Add a DPF cleaning additive to your fuel tank to help break down soot and ash.
5. Replace the DPF: If the filter is too clogged, it may need replacement.

For step-by-step guidance on how to perform these tasks and maintain your DPF, download our 2009 Ford C-Max 2.0 TDCi Zetec DPF Workshop Service & Repair Manual (PDF).

1. Inspect the Turbo: Check for visible signs of damage, oil leaks, or excessive play in the turbo shaft.
2. Check the Air Filter: A clogged air filter can restrict airflow, leading to turbocharger problems. Replace the filter if necessary.
3. Examine the Intercooler: Ensure the intercooler is clean and free of obstructions.
4. Look for Leaks: Check for any air leaks in the hoses connected to the turbocharger.
5. Test the Wastegate: A malfunctioning wastegate can cause over-boost or under-boost conditions. Test and replace if needed.

Detailed instructions on turbocharger inspection, testing, and replacement can be found in our 2009 Ford C-Max 2.0 TDCi Zetec DPF Workshop Service & Repair Manual (PDF).

1. Clean the EGR Valve: Remove the EGR valve and clean it thoroughly with a carburetor cleaner to remove carbon deposits.
2. Inspect for Damage: Check the valve and associated components for any signs of wear or damage. Replace any faulty parts.
3. Test the EGR Valve: Use a vacuum pump to test the valve's operation. If it fails to open or close properly, it may need to be replaced.
4. Check EGR Cooler: Ensure the EGR cooler is not clogged or leaking, as this can also cause valve issues.

For comprehensive guidance on EGR valve maintenance and repair, consult our 2009 Ford C-Max 2.0 TDCi Zetec DPF Workshop Service & Repair Manual (PDF).

1. Run Diagnostic Tests: Use an OBD-II scanner to check for any error codes related to the injectors.
2. Inspect Injectors: Remove and visually inspect the injectors for signs of damage, such as leaks or carbon build-up.
3. Clean the Injectors: Use a fuel injector cleaning kit to remove deposits that may be affecting performance.
4. Test Fuel Pressure: Ensure that the fuel pressure is within the specified range. Low pressure can indicate a faulty injector.
5. Replace Faulty Injectors: If cleaning does not resolve the issue, you may need to replace one or more injectors.

Our 2009 Ford C-Max 2.0 TDCi Zetec DPF Workshop Service & Repair Manual (PDF) provides detailed steps for diagnosing and fixing injector problems.

1. Inspect the Clutch: Check for signs of wear, such as a slipping or stiff clutch pedal. If the clutch is worn out, it needs to be replaced.
2. Examine the Flywheel: Inspect the dual-mass flywheel for excessive play or damage. If it is worn or damaged, it should be replaced along with the clutch.
3. Check Hydraulic System: Ensure the clutch hydraulic system is functioning correctly and there are no leaks in the master or slave cylinder.
4. Replace Components: Replace the clutch, flywheel, and any associated components as needed. It's often recommended to replace both the clutch and flywheel together to avoid future issues.

For a complete guide on replacing your clutch and dual-mass flywheel, refer to our 2009 Ford C-Max 2.0 TDCi Zetec DPF Workshop Service & Repair Manual (PDF).