Page 1785 of 4402
Intake \bir Di\ftribution and Filtering - 1.8L
Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS)
- Lynx - \bir Cleaner
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
In\ftallation 1.
Torque:\b 3
\fNm\f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h
e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 1786 of 4402
Intake \bir Di\ftribution and Filtering - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) -
DW/2.0L Duratorq-TDCi (103kW/140PS)
- DW/2.0L Duratorq-TDCi
(118kW/160PS) - DW, Emi\f\fion
Requirement\f: Stage IV/Stage V - Intake
\bir Di\ftribution and Filtering
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
De\fcription and Operation
\f\f
De\fcription
Int\bke\f\bir\fshutoff\fthrottle\f
Air\fcle\bner\foutlet\fpipe\f
Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fhose\f
M\bss\f\bir\fflow\f(MAF)\fsensor\f
Air\fcle\bner\fcover\f
Air\fcle\bner\felement\f
Air\fcle\bner\fhousing\f
Air\fcle\bner\fint\bke\fpipe\f
Noise,\fvibr\btion\f\bnd\fh\brshness\f(NVH)\ffo\bm\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f
Item
1
2
3
4
5
6
7
8
9
10
\f
Part Number -
-
-
-
-
-
-
-
-
-
-
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Page 1787 of 4402
Ch\brge\f\bir\fcooler\f
Turboch\brger\f
Ch\brge\f\bir\fcooler\foutlet\fpipe\f
11
12
13
-
-
-
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Page 1788 of 4402
Intake \bir Di\ftribution and Filtering - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) -
DW/2.0L Duratorq-TDCi (103kW/140PS)
- DW/2.0L Duratorq-TDCi
(118kW/160PS) - DW, Emi\f\fion
Requirement\f: Stage IV/Stage V - \bir
Cleaner
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
In\ftallation 1.
Torque:\b 3
\fNm\f
1. CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
th
e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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Page 1789 of 4402
Intake \bir Di\ftribution and Filtering - 2.0L
Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) -
DW/2.0L Duratorq-TDCi (103kW/140PS)
- DW/2.0L Duratorq-TDCi
(118kW/160PS) - DW, Emi\f\fion
Requirement\f: Stage IV/Stage V - Charge
\bir Cooler
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
All\fvehicles\f
Ve
hicles\fwith\f2.5L\fengine\f
All\fvehicles\f
1. R\bise\f\bnd\fsupport\fthe\fvehicle.\f
Re
fer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des
cription\f\bnd\fOper\btion).\f
2. \f
3. \f
4. \f
5. \f\f 1.Torque:\b 5\fNm
\f
2. Torque:\b 5\fNm
\f
\f\f
\f\f
\f\f
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Page 1790 of 4402
In\ftallation 1.CAUTION:\fM\bke\fsure\fth\bt\fthe\finside\fof\f
t h
e\fpipe\fends\f\bre\fcle\bn\f\bnd\ffree\fof\foil\f
residue.\f To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
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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*
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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
*
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