ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

ABOUT US
Diagnosis and Testing|Removal and Installation > < 303-04H Fuel Charging and Controls - Turbocharger - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications

Mondeo 2007.5 (02.2007-)

Fuel Charging and Controls - Turbocharger - 1.8L Duratorq-TDCi (Lynx) Diesel - Turbocharger Mondeo 2007.5 (02/2007-)
Diagnosis and Testing

General Equipment
Worldwide Diagnostic System (WDS)

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 or electrical damage.

Visual Inspection Chart

Mechanical Electrical
  • Oil leak(s)
  • Air cleaner element
  • Air cleaner outlet pipe
  • Air cleaner intake pipe
  • Turbocharger oil supply pipe
  • Turbocharger oil return tube
  • Turbocharger intake pipe
  • Turbocharger housing
  • Charge air cooler
  • Charge air cooler intake pipe and hose(s)
  • Charge air cooler outlet pipe and hose(s)
  • Wiring harness
  • Turbocharger electronic actuator
  • PCM
  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 turbine 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
*
Charge air cooler system.
*
CHECK the charge air cooler, charge air cooler pipes and charge air cooler hoses for leaks and obstructions. REPAIR as necessary.
*
Air cleaner intake pipe.
*
CHECK the air cleaner intake pipe for obstruction. REPAIR the necessary.
*
Turbocharger electronic actuator.
*
REFER to WDS.

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
Location of the engine upper cover retaining clips.

CAUTION:
CAUTION:Care must be taken when releasing the fourth retaining clip and maneuvering the engine upper cover past the manifold absolute pressure (MAP) sensor. Failure to follow this instruction may result in damage to the MAP sensor.
NOTE:
NOTE:Only remove and install the engine upper cover in the sequence shown.
2
Remove the engine upper cover.

3
Detach the turbocharger intake pipe and position it to one side.

4
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 - 1.8L Duratorq-TDCi (Kent) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Removal and Installation).
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 - 1.8L Duratorq-TDCi (Kent) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Removal and Installation).
TEST the system for normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
1
Remove the turbocharger.
REFER to: Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (303-04F, Removal and Installation).
2
Using workshop compressed air and a compressed air nozzle, check the oil supply tube for blockage.

Is the oil supply tube free from blockage?
Yes
GO to A5.
No
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Removal and Installation).
TEST the system for normal operation.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE

1
Visually inspect the oil supply tube oil gallery for blockage.

Is the oil supply tube oil gallery free from blockage?
Yes
INSTALL a new turbocharger and oil supply pipe.
REFER to: Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Removal and Installation).
TEST the system for normal operation.
No
REMOVE the blockage. INSTALL a new turbocharger.
REFER to: Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (303-04F Fuel Charging and Controls - Turbocharger, Removal and Installation).
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
Raise and support the vehicle. For additional information,
REFER to: Lifting (100-04 Noise, Vibration and Harshness, Description and Operation).

2
Remove the engine undershield.

NOTE:
NOTE:Discard the gasket(s).
3
Remove the turbocharger oil return pipe.
4
Check the turbocharger oil return pipe for blockage or signs of damage.

Is the turbocharger oil return pipe free from blockage and signs of damage?
Yes
GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls (303-04 Fuel Charging and Controls - 2.0L Duratorq-TDCi (DW) Diesel, Diagnosis and Testing).
No
INSTALL a new turbocharger oil return pipe. TEST the system for normal operation.

Diagnosis and Testing|Removal and Installation > < 303-04H Fuel Charging and Controls - Turbocharger - 1.8L Duratorq-TDCi (Lynx) Diesel|Specifications