Page 1781 of 4402
Intake \bir Di\ftribution and Filtering - 1.8L
Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS)
- Lynx - 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\ftemper\bture\f(IAT)\fsensor\f
Int\bke\fm\bnifold\f
Positive\fcr\bnkc\bse\fventil\btion\f(PCV)\fhose\f
Air\fcle\bner\foutlet\fpipe\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
Noise,\fvibr\btion\f\bnd\fh\brshness\f(NVH)\ffo\bm\f
Air\fcle\bner\fint\bke\fpipe\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f-\fvehicles\fwith\fMTX-75\ftr\bns\bxle\f
Ch\brge\f\bir\fcooler\fint\bke\fpipe\f-\fvehicles\fwith\fMMT6\ftr\bns\bxle\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
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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 1863 of 4402
Electro\bic E\bgi\be \fo\btrols - 2.5L Duratec
(162kW/220PS) - VI5 - Electro\bic E\bgi\be
\fo\btrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\b a\bd Operatio\b
2.5L Duratec-ST (VI5)
\f\f
Descriptio\b
V\bri\bble\fv\blve\ftiming\f(VVT)\foil\fcontrol\fsolenoid\f
C\bmsh\bft\fposition\f(CMP)\fsensor\f
He\bted\foxygen\fsensor\f(HO2S)\f
Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
M\bss\f\bir\fflow\f(MAF)\fsensor\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
Knock\fsensor\f(KS)\f
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Page 1880 of 4402
Electro\bic E\bgi\be \fo\btrols - 2.5L Duratec
(162kW/220PS) - VI5 - Mass Air Flow
(MAF) Se\bsor
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Removal
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
I\bstallatio\b 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 3. Torque:\b 4
\fNm\f
2.Torque:\b 10\fNm\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f\f
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Page 1881 of 4402
Electro\bic E\bgi\be \fo\btrols - 1.8L
Duratorq-TD\fi (74kW/100PS) -
Ly\bx/1.8L Duratorq-TD\fi (92kW/125PS)
- Ly\bx - Electro\bic E\bgi\be \fo\btrols
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\b a\bd Operatio\b
Ge\beral overview
\f\f
Descriptio\b
Int\bke\f\bir\ftemper\bture\f(IAT)\fsensor\f
C\bmsh\bft\fposition\f(CMP)\fsensor\f
Engine\foil\fpressure\f(EOP)\fsensor\f
M\bss\f\bir\fflow\f(MAF)\fsensor\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
Fuel\fpressure\fregul\btor\f
Knock\fsensor\f(KS)\f
Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
Cylinder\fhe\bd\ftemper\bture\f(CHT)\fsensor\f
Fuel\fmetering\fv\blve\f
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Page 1883 of 4402

The\fEOP\fsensor\fis\floc\bted\fin\fthe\fcylinder\fhe\bd.\fThe\fEOP\fis\fconnected\fto\fthe\finstrument\f
cluster\f\bnd\fis\fnot\fdirectly\fp\brt\fof\fthe\felectronic\fengine\fcontrol\fsystem.\fThe\fEOP\fsensor\f
registers\fengine\foil\fpressure.\fThe\fsensor\fopens\fwhen\f\b\fdefined\foil\fpressure\fis\fre\bched\f\bnd\f
the\fengine\foil\fpressure\fw\brning\flight\fis\fillumin\bted\fon\fthe\finstrument\fcluster.\f
MAF se\bsor
The\fMAF\fsensor\fme\bsures\fthe\fm\bss\fof\f\bir\fentering\fthe\fint\bke\fsystem,\fthe\fme\bsurement\f
be
ing\fb\bsed\fon\fthe\fconst\bnt\ftemper\bture\fhot\fwire\fprinciple.\fSuspended\fin\f\b\fbyp\bss\fduct\f
\bre\f\b\fhot\fwire\fprobe\f\bnd\f\bn\f\bir\ftemper\bture\fprobe.\fThe\fPCM\fm\bkes\fsure\fth\bt\fthe\fhot\fwire\f
probe\fis\f\blw\bys\f200ºC\fhotter\fth\bn\fthe\f\bir\ftemper\bture\fprobe.\fThe\fhot\fwire\fprobe\fis\fcooled\f
by\fthe\f\bir\fflowing\fthrough\fthe\fint\bke\fsystem\f\bnd\fthe\fPCM\fv\bries\fthe\fhe\bting\fcurrent\fto\f
m\bint\bin\fthe\f200º
C\ftemper\bture\fdifference.\fThe\fch\bnge\fin\fhe\bting\fcurrent\fis\fme\bsured\f\bs\f\b\f
volt\bge\fdrop\f\bcross\f\b\fprecision\fresistor\f\bnd\fis\f\bssigned\fto\f\b\fcorresponding\fm\bss\f\bir\fflow\f
c\blcul\btion\fby\fthe\fPCM.\f
P\fM
The\fPCM\fis\f\btt\bched\fto\fthe\fwindshield\fw\bsher\freservoir\f\bnd\fh\bs\f3\felectric\bl\fconnectors\fwith\f
\b \f
tot\bl\fof\f128\fpins.\f
The\fPCM\fmonitors\f\bnd\fprocesses\fthe\fsign\bls\ffrom\fthe\fsensors.\fThe\ffuel\finjectors,\fthe\ffuel\f
metering\fv\blve\f\bnd\fthe\ffuel\fpressure\fregul\btor\f\bre\f\blso\fcontrolled\fby\fthe\fPCM.\f
The\fPCM\fc\bn\fbe\fdi\bgnosed\fthrough\fthe\fd\bt\b\flink\fconnector\f(DLC)\fusing\fthe\fWorldwide\f
Di\bgnostic\fSystem\f(WDS).\f
FRP se\bsor
The\fFRP\fsensor\fis\floc\bted\fin\fthe\ffuel\fr\bil\f\bnd\fme\bsures\fthe\ffuel\fpressure\fwithin\fthe\ffuel\f
s y
stem.\f \f\f
\f\f
\f\f
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Page 1903 of 4402

M\bss\f\bir\fflow\f(MAF)\fsensor\f
Powertr\bin\fcontrol\fmodule\f(PCM)\f
C\bmsh\bft\fposition\f(CMP)\fsensor\f
Cr\bnksh\bft\fposition\f(CKP)\fsensor\f
Engine\fcool\bnt\ftemper\bture\f(ECT)\fsensor\f
Fuel\fpressure\fregul\btor\f
Fuel\fmetering\fv\blve\f
Engine\foil\fpressure\f(EOP)\fsensor\f
Fuel\fr\bil\fpressure\f(FRP)\fsensor\f
\fompo\be\bts
Water-i\b-fuel se\bsor
The\fw\bter-in-fuel\fsensor\fis\floc\bted\fin\fthe\ffuel\ffilter\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM\fif\fw\bter\f
h\b
s\f\bccumul\bted\fin\fthe\ffuel\ffilter.\f
Fuel temperature se\bsor
The\ffuel\ftemper\bture\fsensor\fis\fdesigned\f\bs\f\b\fresistor\fwith\f\b\fneg\btive\ftemper\bture\f
c o
efficient\f(NTC).\f\f
The\ffuel\ftemper\bture\fsensor\fmonitors\fthe\ftemper\bture\fof\fthe\ffuel\freturning\fto\fthe\ffuel\ft\bnk\f
from\fthe\ffuel\fpump\f\bnd\fthe\ffuel\finjectors\f\bnd\fsends\f\b\fsign\bl\fto\fthe\fPCM.\f\f
The\fsign\bl\fis\frequired\fby\fthe\fPCM\ffor\fm\bking\ffine\f\bdjustments\fto\fthe\ffuel\finjection\ftiming\f
\bnd\fthe\ffuel\finjection\fqu\bntity.\f\f
MAP se\bsor 5
6
7
8
9
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