2006 FORD S-MAX air intake

Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Intake ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
General Equipment
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Schlitzschr\bubendreher
Trolley\fj\bck
1.General \bqui\fment: Schlitzschr\bubendreher \f
2. \f
3

. Refer\fto:\f Air\fCle\bner\f(303-12A\fInt\bke\fAir\f
Di s

tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
5. Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
6. \f
7. \f\f 1.Torque: 48\fNm
\f
2. Torque: 80\fNm
\f
\f\f
\f\f
\f\f
Стр. 1 из
3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G898711&gui...procarmanuals.com
http://vnx.su

Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Intake ManifoldS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Refer\fto:\f Pe
trol\f\bnd\fPetrol-Eth\bnol\fFuel\fSystems\f
He\bl
th\f\bnd\fS\bfety\fPrec\butions\f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Fuel\fSystem\fPressure\fRele\bse \f(310-00\f
Fue

l\fSystem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
3. Refer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-
01 \f

B\bttery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
4. Refer\fto:\f Air\fCle\bner\f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
5. \f
6. Torque:\b 10\fNm
\f
7. Torque:\b 10\fNm
\f
8. \f
\f\f
\f\f
\f\f
Стр. 1 из
3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G915548&gui...procarmanuals.com
http://vnx.su

NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets

Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
1
2


Стр. 8 из 21
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1048763&gu...procarmanuals.com
http://vnx.su

Description
C\b\blant return
Oil filter \f\busing
Oil pressure switc\f
Oil c\b\bler
C\b\blant feed
T\fe \bil filter/\bil c\b\bler unit is l\bcated \bn t\fe intake side \bf t\fe engine, level wit\f t\fe t\fird cylinder.
T\fe \bil filter element (paper filter element) is l\bcated in t\fe \bil filter \f\busing.
T\fe c\b\blant is r\buted fr\bm t\fe cylinder bl\bck int\b t\fe \bil c\b\bler via t\fe c\b\blant feed. T\fe c\b\blant is r\buted t\b t\fe t\ferm\bstat
\f\busing \bf t\fe c\b\bling system via t\fe c\b\blant return.
Intake manifold
T\fe intake manif\bld is designed s\b t\fat t\fe c\farge air is r\buted t\b all eig\ft intake ducts in a c\bntr\blled manner.
Furt\ferm\bre, t\fe gas fr\bm t\fe p\bsitive crankcase ventilati\bn system and fr\bm t\fe EGR (ex\faust gas recirculati\bn)
returned t\b t\fe intake manif\bld. T\fe seal wit\f t\fe intake ducts at t\fe cylinder \fead is pr\bvided:

by means \bf \bne O-ring f\br eac\f \bf t\fe f\bur l\bwer swirl ducts,

by means \bf \bne rubber seal f\br eac\f \bf t\fe f\bur upper c\farge ducts.
Note: W\fen fitting t\fe intake manif\bld, ensure t\fat t\fe O-
rings/rubber seals are seated c\brrectly.
T\fe intake manif\bld is b\blted t\b t\fe cylinder \fead using a t\btal \bf seven retaining b\blts. Item
1
2
3
4
5


Стр. 16 из 21
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1048763&gu...procarmanuals.com
http://vnx.su

Intake d\fcts

Description
C\farge duct (in t\fe upper part \bf t\fe cylinder \fead)
Intake manif\bld
Swirl duct
Outlet Duct
C\farge duct (in t\fe l\bwer part \bf t\fe cylinder \fead)
T\fe m\bvement \bf t\fe air fl\bwing int\b t\fe cylinder is crucial f\br \bptimum mixture f\brmati\bn.
Ea
c\f cylinder is equipped wit\f tw\b intake valves. Leading t\b eac\f intake valve is

\bne swirl duct and

\bne c\farge duct.
T\fe swirl d\fct
pr\bduces a specific r\btati\bnal m\bvement (swirl) in t\fe c\farge air. T\fis \bptimises mixture f\brmati\bn in t\fe
lower engine speed range and t\fus reduces fuel c\bnsumpti\bn.
T\fe charge d\fct
guarantees an \bptimum cylinder c\farge at all times. T\fis \fas a p\bsitive effect \bn engine perf\brmance in
t\fe \fpper engine speed range .
Exha\fst Manifolds Item
1
2
3
4
5

Стр. 17 из 21
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1048763&gu...procarmanuals.com
http://vnx.su

Description
C\bnnecting pipe leading fr\bm EGR valve t\b intake manif\bld
T\fr\bttle b\bdy
Intake manif\bld
Ex\faust Manif\blds
C\b\blant inlet p\brt
EGR radiat\br
C\b\blant \butlet c\bnnecti\bn
EGR valve
Diesel engines w\brk wit\f a large surplus \bf air. T\fe \fig\f pr\bp\brti\bn \bf O2
(\bxygen) pr\bduces a \fig\f pr\bp\brti\bn \bf
(\bxides \bf nitr\bgen) during c\bmbusti\bn.
Via
t\fe EGR system, part \bf t\fe ex\faust gas is r\buted back int\b t
\fe fres\f air fl\bw.
T\fe pr\bp\brti\bn \bf recirculated ex\faust gas n\b l\bnger directly participates in t\fe c\bmbusti\bn. T\fis significantly reduces t\fe
pr\bp\brti\bn \bf NOX.
T\fe ex\faust gas recirculati\bn rate depends t\b a large extent \bn t\fe engine speed and engine l\bad. T\fe ex\faust gas can be
recirculated particularly efficiently in t\fe l\bwer partial l\bad range. Recirculati\bn rates \bf \bver 60% are p\bssible under
fav\burable c\bnditi\bns.
EGR valve and radiator
Item
1
2
3
4
5
6
7
8

Стр. 20 из 21
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1048763&gu...procarmanuals.com
http://vnx.su

Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\f
REFER\fto:\f
Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
Стр. 3 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su

Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\fof\f
foreign\fm\bteri\bl.\f1
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\f\b\f
new\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
GO\fto\fA4.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\fwithin\f
the\fhousing.\f

1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\fthe\f
sh

\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\fbottom\fof\f
the\fbe\brings).\f

2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwith\fno\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No I

NSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
Remove\fthe\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f2
\f\f
\f\f
Стр. 3 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G469392&gui...procarmanuals.com
http://vnx.su