ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Diagnosis and Testing|Removal and Installation > < 303-04C Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel|Specifications

Fusion 2002.75 (06.2002-)

Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel - Turbocharger Fusion 2002.75 (06/2002-)
Diagnosis and Testing

Special Tool(s)

Boost Pressure Gauge

310-020 (23-021)

Inspection and Verification

NOTE:
NOTE:It is normal for a small amount of combustion gas to pass into the crankcase. This gas is scavenged into the air intake system through the positive crankcase ventilation (PCV) system, which incorporates an oil separator. Some engine oil, in the form of a vapor is carried into the air intake system with the blow-by gases (this engine oil also contributes to valve seat durability). This means that oil will collect inside the air intake components and the turbocharger. This is not an indication that the turbocharger oil seal has failed. The turbocharger oil seal will not fail unless the bearings fail first, which will cause the turbocharger to become noisy or seize. Do not install a new turbocharger due to oil inside the turbocharger or the air intake components. If a leak is detected in the oil supply or return tubes or connections, locate and rectify the source. Do not install a new turbocharger due to an oil leak.
  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical
Oil leak(s)
Air cleaner element
Turbocharger intake tube
Air cleaner intake pipe
Turbocharger oil supply or oil return tube
Wastegate control valve
Turbocharger housing
Wastegate control pipe
Catalytic converter
  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 Chart

Symptom Possible Sources Action
Blue smoke with excessive turbocharger noise
*
Turbocharger compressor rubbing on housing walls.
*
Turbocharger bearings and oil seal(s).
*
Turbocharger oil supply tube blocked or damaged.
*
GO to Pinpoint Test A. .
Blue smoke without excessive turbocharger noise
*
Turbocharger oil return tube blocked or damaged.
*
GO to Pinpoint Test B. .
Poor engine performance
*
Wastegate control valve actuator rod.
*
CHECK the wastegate control valve actuator rod moves freely, If the wastegate control valve actuator rod does not move freely. CHECK for signs of damage or signs of foreign material. INSTALL a new turbocharger.
REFER to Turbocharger - in this section.
TEST the system for normal operation.
*
Turbocharger boost pressure incorrect.
*
The boost pressure is factory set and must not be adjusted. CHECK the paint seal on the actuator rod has not been broken. If the paint seal has been broken, INSTALL a new turbocharger.
REFER to Turbocharger - in this section.
TEST the system for normal operation.
*
If the paint seal has not been broken, GO to Pinpoint Test C.

Pinpoint Tests

PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE

1
Remove the air cleaner outlet pipe.

2
Inspect the turbocharger rotor vanes for damage.

Is there visible damage to the rotor vanes?
Yes
GO to A2. .
No
GO to A3. .
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
1
Check the intake air system components for signs of foreign material.

Are there any signs of foreign material?
Yes
CLEAN the intake air system components. INSTALL a new turbocharger.
REFER to Turbocharger - in this section.
TEST the system for normal operation.
No
GO to A4. .
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:
NOTE:A small amount of movement in the bearings is normal.

1
Make sure the turbocharger rotor spins freely within the housing.
  • 1. With the turbocharger stationary, gently lift the shaft (the shaft will naturally lay in the bottom of the bearings).
  • 2. Make sure the rotor spins freely within the housing.

Does the rotor spin freely within the housing with no excessive movement?
Yes
GO to A4. .
No
INSTALL a new turbocharger.
REFER to Turbocharger - in this section.
TEST the system for normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE

1
Disconnect the oil supply tube from the turbocharger.
2
Attach a small piece of known good hose to the oil supply tube and gently blow down the hose.

Are there any signs of blockage?
Yes
INSTALL a new turbocharger oil supply tube. TEST the system for normal operation.
No
INSTALL a new turbocharger.
REFER to Turbocharger - in this section.
TEST the system for normal operation.

PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE

1
Remove the turbocharger oil return tube (catalytic converter shown removed for clarity).
2
Check the turbocharger oil return tube for a blockage or signs of damage.

Is the turbocharger oil return tube OK?
Yes
GO to Fuel Charging and Controls for further diagnostics. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls - Turbocharger / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
No
INSTALL a new turbocharger oil return tube. TEST the system for normal operation.

PINPOINT TEST C : POOR ENGINE PERFORMANCE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE BOOST PRESSURE
NOTE:
NOTE:The boost pressure is factory set and must not be adjusted.
1
Using a boost pressure gauge and a T connector, connect the gauge between the wastegate control actuator and the turbocharger.
2
Start and run the engine until the cooling fan has operated.
3
Raise the engine speed to 3000 rpm and observe the reading.

Is the boost pressure 0.5 bar?
Yes
GO to Fuel Charging and Controls for further diagnostics. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls - Turbocharger / 303-04D Fuel Charging and Controls / 303-04E Fuel Charging and Controls - Turbocharger.
No
INSTALL a new turbocharger.
REFER to Turbocharger - in this section.
TEST the system for normal operation.

Diagnosis and Testing|Removal and Installation > < 303-04C Fuel Charging and Controls - Turbocharger - 1.4L Duratorq-TDCi (DV) Diesel|Specifications