Ford Workshop Service and Repair Manuals > S-MAX.Galaxy 2006.5 (03.2006-) > Mechanical Repairs | 3 Powertrain | 303 Engine | 303-04H Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (DW) Diesel | Description and Operation | Diagnosis and Testing

Diagnosis and Testing|Removal and Installation > < Turbocharger

Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (DW) Diesel - Turbocharger

S-MAX/Galaxy 2006.5 (03/2006-)

Diagnosis and Testing

Special Tool(s)

Hand Vacuum/Pressure Pump

416 - D001 (23 - 036A)

Fuel Pressure Gauge

310-053 (23-046)

General Equipment

Worldwide Diagnostic System (WDS) (418-F224)

Inspection and Verification

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.

Verify the customer concern.

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 or oil return tube Turbocharger intake pipe Turbocharger vacuum diaphragm unit Turbocharger housing Charge air cooler Charge air cooler intake pipe and hose(s) Charge air cooler outlet pipe and hose(s)	Wiring harness Vane adjustment solenoid valve PCM

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

NOTE:The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or renewed.

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	* Vacuum diaphragm unit vacuum line(s).	* CHECK all vacuum line(s) are installed and no signs of air leaks are present. REPAIR as necessary.
	* 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.
	* Unauthorized adjustment of the vacuum diaphragm unit actuator rod.	* The turbocharger boost pressure is factory set and must not be adjusted. CHECK the paint seal on the vacuum diaphragm unit actuator rod has not been broken. If the paint seal has been broken, INSTALL a new turbocharger. REFER to: Turbocharger (303-04I Fuel Charging and Controls - Turbocharger - 2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
	* Vacuum diaphragm unit actuator rod.	* CHECK the vacuum diaphragm unit actuator rod moves freely, If the vacuum diaphragm unit actuator rod does not move freely. CHECK for signs of damage or signs of foreign material. REPAIR as necessary.
	* Turbocharger boost pressure.	* GO to Pinpoint Test C.