Page 1761 of 2057
Engine Emission Control
2.5L Duratec-ST (VI5)
Engine Emission Components
23
4
1
E66306
G510285en2008.50 Kuga8/2011
303-08-
2
Engine Emission Control— 2.5L Duratec (147kW/200PS) - VI5303-08-
2
DESCRIPTION AND OPERATION
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Page 1762 of 2057
Description
Item
Intake manifold to turbocharger breather
hose
1
Crankcase vent oil separator to valve
cover hose
2
Crankcase vent oil separator to intake
manifold hose
3
Crankcase vent oil separator
4
G510285en2008.50 Kuga8/2011
303-08- 3
Engine Emission Control— 2.5L Duratec (147kW/200PS) - VI5303-08-
3
DESCRIPTION AND OPERATION
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Page 1763 of 2057

Engine Emission Control
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Electrical
Mechanical
– Electricalconnector(s)
– Wiring harness
– Fuse(s)
– Relay
– Powertain control module (PCM)
– Hose(s)/hose joints
– Gasket(s)
– Positive crankcase
ventilation (PCV)
valve
– PCV crankcase vent oil separator
– Turbocharger 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CLEAN or INSTALL new PCVcomponents as necessary.
TEST the system for normal
operation.
• Blocked PCV crankcase vent
oil separator.
• Blocked PCV hose.
• Excessive crankcase pressure
• Worn or damaged enginecomponents.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Engine.
• CLEAN or INSTALL a newcrankcase vent oil separator.
TEST the system for normal
operation.
• Crankcase vent oil separator.
• Oil in the air intake system
• Worn or damagedturbocharger.
REFER to: Turbocharger (303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
G1183446en2008.50 Kuga8/2011
303-08-
4
Engine Emission Control— 2.5L Duratec (147kW/200PS) - VI5303-08-
4
DIAGNOSIS AND TESTING
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Page 1764 of 2057
Action
Possible Sources
Symptom
• Worn or damaged enginecomponents.
REFER to: Engine(303-00
Engine System - General
Information, Diagnosis and
Testing).
• Excessive crankcase pressure.
G1183446en2008.50 Kuga8/2011
303-08-
5
Engine Emission Control— 2.5L Duratec (147kW/200PS) - VI5303-08-
5
DIAGNOSIS AND TESTING
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Page 1765 of 2057

SECTION 303-12 Intake Air Distribution and Filtering
— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
303-12-2
Intake Air Distribution and Filtering (Component Location) ................................................
DIAGNOSIS AND TESTING 303-12-4
Intake Air Distribution and Filtering ........................................................................\
.............
303-12-4
Inspection and Verification ........................................................................\
..........................
303-12-4
Symptom Chart ........................................................................\
...........................................
REMOVAL AND INSTALLATION 303-12-6
(23 174 0)
Air Cleaner ........................................................................\
..............................
303-12-8
(23 620 0)
Charge Air Cooler ........................................................................\
...................
303-12-1
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 1
.
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Page 1766 of 2057
Intake Air Distribution and Filtering – Component Location
E105576
1
2
34
5
6
7
8
9
Description
Item
Intake manifold
1
Air cleaner
2
The MAF (mass air flow) sensor
3
Pipe, air filter to turbocharger
4Description
Item
Turbocharger
5
Pipe, turbocharger to intercooler
6
Charge air cooler
7
Pipe, intercooler to intake manifold
8
Air Intake manifold
9
G1079094en2008.50 Kuga8/2011
303-12- 2
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 2
DESCRIPTION AND OPERATION
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E105848
1
2
3
Description
Item
Throttle body mechanism
Comments:Incorporates the TP (throttle position)
sensor
1
PCM (powertrain control module) cover
2
The MAPT (manifold absolute pressure
and temperature) sensor
3
G1079094en2008.50 Kuga8/2011
303-12-
3
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 3
DESCRIPTION AND OPERATION
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Page 1768 of 2057

Intake Air Distribution and Filtering
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicalor electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Mass air flow (MAF)sensor
– Manifold absolute pressure (MAP)
sensor
– Electrical connector(s)
– Air cleaner element
– Air cleaner intake
pipe
– Air cleaner outlet pipe
– Charge air cooler
– Charge air cooler intake pipe
– Charge air cooler outlet pipe 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Action
Possible Sources
Symptom
• CHECK the pipe(s) for securityand leaks to atmosphere.
INSTALL new intake air
components as necessary.
TEST the system for normal
operation.
• Detached air cleaner pipe(s).
• Detached turbocharger pipe(s).
• Detached charge air cooler
pipe(s).
• Excessive intake air noise
• REFER to:Engine Emission
Control (303-08 Engine
Emission Control - 2.5L
Duratec (147kW/200PS) -
VI5, Diagnosis and Testing).
• Blocked or damaged PCV
pipe(s)/hose(s).
• Blocked or damaged crankcase vent oil separator.
• Oil in the air intake system
• REFER to:Turbocharger(303-
04 Fuel Charging and
Controls - Turbocharger -
2.5L Duratec (147kW/200PS)
- VI5, Diagnosis and Testing).
• Turbocharger.
• CHECK the air intake pipesplash shield for correct install-
ation and alignment.
REPAIR/INSTALL the air intake
pipe splash shield as neces-
sary. TEST the system for
normal operation.
• Air intake pipe splash shield.
• Water in the air cleaner
G1183447en2008.50 Kuga8/2011
303-12- 4
Intake Air Distribution and Filtering
— 2.5L Duratec
(147kW/200PS) - VI5
303-12- 4
DIAGNOSIS AND TESTING
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