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Diagnosis and Testing|Removal and Installation > < Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi (DW) Diesel

Focus 2004.75 (07.2004-)

Intake Air Distribution and Filtering - Intake Air Distribution and Filtering Focus 2004.75 (07/2004-)
Diagnosis and Testing

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Air cleaner element
  • Air cleaner intake hose
  • Air cleaner outlet hose
  • Charge air cooler (Vehicles with 1.6L Diesel and 2.0L Diesel engine)
  • Charge air cooler intake hose (Vehicles with 1.6L Diesel and 2.0L Diesel engine)
  • Charge air cooler outlet hose (Vehicles with 1.6L Diesel and 2.0L Diesel engine)
  • Mass air flow (MAF) sensor
  • Manifold absolute pressure (MAP) sensor (Vehicles with 1.6L Diesel and 2.0L Diesel engine)
  • Electrical connector(s)
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Symptom Possible Sources Action
Excessive intake air noise
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Detached air cleaner hose(s).
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Detached turbocharger hose(s) (Vehicles with 1.6L Diesel and 2.0L Diesel engine).
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Detached charge air cooler hose(s) (Vehicles with 1.6L Diesel and 2.0L Diesel engine).
*
CHECK the hose(s) for security and leaks to atmosphere. INSTALL new intake air components as necessary. TEST the system for normal operation.
Oil in the air intake system
*
Blocked or damaged positive crankcase ventilation (PCV) valve.
*
Blocked or damaged PCV pipe(s)/hose(s).
*
Blocked or damaged crankcase vent oil separator.
*
Vehicles with 1.6L engine. REFER to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control / 303-08C Engine Emission Control / 303-08D Engine Emission Control / 303-08F Engine Emission Control / 303-08G Engine Emission Control.
*
Vehicles with 1.8L/2.0L engine. REFER to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control / 303-08C Engine Emission Control / 303-08D Engine Emission Control / 303-08F Engine Emission Control / 303-08G Engine Emission Control.
*
Vehicles with 1.6L Diesel engine. REFER to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control / 303-08C Engine Emission Control / 303-08D Engine Emission Control / 303-08F Engine Emission Control / 303-08G Engine Emission Control.
*
Vehicles with 2.0L Diesel engine. REFER to Section  303-08A Engine Emission Control / 303-08B Engine Emission Control / 303-08C Engine Emission Control / 303-08D Engine Emission Control / 303-08F Engine Emission Control / 303-08G Engine Emission Control.
*
Turbocharger (Vehicles with 1.6L Diesel and 2.0L Diesel engine).
*
Vehicles with 1.6L and 2.0L Diesel engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls / 303-04H Fuel Charging and Controls / 303-04I Fuel Charging and Controls - Turbocharger.
Water in the air cleaner
*
Air intake pipe splash shield.
*
CHECK the air intake pipe splash shield for correct installation and alignment. REPAIR/INSTALL the air intake pipe splash shield as necessary. TEST the system for normal operation.
*
Blocked air cleaner drain.
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CHECK the air cleaner drain for blockage. TEST the system for normal operation.
Engine lacks power
*
Air cleaner element blocked.
*
INSPECT the air cleaner for signs of blockage. INSTALL a new air cleaner element as necessary.
*
Charge air cooler pipe(s) (Vehicles with 1.6L Diesel and 2.0L Diesel engine).
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INSPECT the charge air cooler pipes for damage. INSTALL a new charge air cooler pipe(s) as necessary.
*
Charge air cooler blocked (Vehicles with 1.6L Diesel and 2.0L Diesel engine).
*
INSPECT the charge air cooler for blockage. INSTALL a new charge air cooler as necessary.
REFER to Charge Air Cooler - 1.6L Diesel/2.0L Diesel in this section.
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Fuel charging and controls
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Vehicles with 1.6L engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls / 303-04H Fuel Charging and Controls / 303-04I Fuel Charging and Controls - Turbocharger.
*
Vehicles with 1.8L/2.0L engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls / 303-04H Fuel Charging and Controls / 303-04I Fuel Charging and Controls - Turbocharger.
*
Vehicles with 1.6L Diesel engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls / 303-04H Fuel Charging and Controls / 303-04I Fuel Charging and Controls - Turbocharger.
*
Vehicles with 2.0L Diesel engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls / 303-04H Fuel Charging and Controls / 303-04I Fuel Charging and Controls - Turbocharger.
*
Turbocharger (Vehicles with 1.6L Diesel and 2.0L Diesel engine).
*
Vehicles with 1.6L and 2.0L Diesel engine. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger / 303-04F Fuel Charging and Controls / 303-04G Fuel Charging and Controls / 303-04H Fuel Charging and Controls / 303-04I Fuel Charging and Controls - Turbocharger.

Diagnosis and Testing|Removal and Installation > < Intake Air Distribution and Filtering - 2.0L Duratorq-TDCi (DW) Diesel