ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

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Turbocharger - Vehicles Built From: 08-2006 75 PS-90 PS-110 PS, Vehicles With: Variable Vane Turbocharger > < Turbocharger - Vehicles Built Up To: 08-2006 75 PS-90 PS

Transit.Tourneo Connect 2002.5 (06.2002-)

Fuel Charging and Controls - Turbocharger - Turbocharger—Vehicles Built From: 08/2006 75 PS/90 PS/110 PS, Vehicles With: Fixed Vane Turbocharger Transit/Tourneo Connect 2002.5 (06/2002-)
Diagnosis and Testing

Special Tool(s)

Hand Vacuum/Pressure Pump

416-D001 (23-036A)
General Equipment
Worldwide Diagnostic System (WDS)

Inspection and Verification

NOTE:
NOTE:The turbocharger uses engine oil as a lubricant and coolant. Due to the high operating temperatures of the turbocharger and with the expansion and contraction of the internal components a proportion of engine oil may enter the air intake system. 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. Do not install a new turbocharger due to oil inside the turbocharger or the air intake components. If a leak is detected in the 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
  • Air cleaner outlet pipe
  • Air cleaner intake pipe
  • Turbocharger oil supply tube
  • Turbocharger oil return tube
  • Wastegate control valve
  • Turbocharger housing
  • Charge air cooler
  • Charge air cooler intake pipe and hose(s)
  • Charge air cooler outlet pipe and hose(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

CAUTION:
CAUTION:On vehicles with a fixed vane turbocharger the wastegate control valve and actuator rod are fixed parts of the turbocharger and must not be adjusted or renewed separately.

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 and charge air cooler pipe(s) for leaks and obstructions. REPAIR as necessary.
*
Air cleaner intake pipe.
*
CHECK the air cleaner intake pipe for obstructions. REPAIR as necessary.
*
Unauthorized adjustment of the wastegate control valve actuator rod.
*
The wastegate control valve actuator rod is factory set and must not be adjusted. CHECK the paint seal on the wastegate control valve actuator rod has not been broken. If the paint seal has been broken, INSTALL a new turbocharger.
REFER to: Turbocharger - 1.8L Duratorq-TDCi (Kent) Diesel (110 PS), Vehicles With: Fixed Vane Turbocharger (303-04C, Removal and Installation).
*
Wastegate control valve actuator.
*
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

CAUTION:
CAUTION:Make sure that the inside of the pipe ends are clean and free of oil residue.
1
Remove the turbocharger intake 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 - 110 PS, Vehicles With: Fixed Vane Turbocharger (303-04C, 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.
NOTE:
NOTE:The initial rotor rotation of a cold turbocharger may feel rough and uneven but should rotate freely after a few turns.

1
Make sure that 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 that the rotor spins freely within the housing.

Does the rotor spin freely within the housing?
Yes
GO to A4.
No
INSTALL a new turbocharger.
REFER to: Turbocharger - 110 PS, Vehicles With: Fixed Vane Turbocharger (303-04C, Removal and Installation).
TEST the system for normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE

1
Remove the turbocharger oil supply tube.
2
Using workshop compressed air and a compressed air nozzle, check the oil supply tube for blockage.

Is there any signs of blockage?
Yes
GO to A5.
No
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - 110 PS, Vehicles With: Fixed Vane Turbocharger (303-04C, 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 in the cylinder block for blockage.

Is the oil supply tube oil gallery free from blockage?
Yes
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - 110 PS, Vehicles With: Fixed Vane Turbocharger (303-04C, Removal and Installation).
TEST the system for normal operation.
No
REMOVE the blockage. INSTALL a new turbocharger.
REFER to: Turbocharger - 110 PS, Vehicles With: Fixed Vane Turbocharger (303-04C, 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 TUBE

1
Remove the turbocharger oil return tube.
2
Check the turbocharger oil return tube for a blockage or signs of damage.

Is the turbocharger oil return tube blocked?
Yes
GO to Fuel Charging and Controls for further blue smoke diagnostics.
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
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 WASTEGATE ACTUATOR CONTROL LINE FOR BLOCKAGE
1
Remove the wastegate actuator control line.

2
Install the special tool to one end of the wastegate actuator control line.
3
Operate the hand vacuum pump and observe the reading.

Is a reading present?
Yes
INSTALL a new wastegate actuator control line. TEST the system for normal operation.
No
GO to C2.
C2: CHECK THE WASTEGATE ACTUATOR DIAPHRAGM FOR LEAKS

1
Connect the free end of the wastegate control line to the wastegate actuator.
2
Operate the hand vacuum pump and observe the reading.

Does the pump hold vacuum?
Yes
GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls - Vehicles Built From: 08/2006 75 PS/90 PS/110 PS (303-04B Fuel Charging and Controls - 1.8L Duratorq-TDCi (Lynx) Diesel/1.8L Duratorq-TDDi (Lynx) Diesel, Diagnosis and Testing).
No
INSTALL a new turbocharger.
REFER to: Turbocharger - 110 PS, Vehicles With: Fixed Vane Turbocharger (303-04C, Removal and Installation).
TEST the system for normal operation.

Turbocharger - Vehicles Built From: 08-2006 75 PS-90 PS-110 PS, Vehicles With: Variable Vane Turbocharger > < Turbocharger - Vehicles Built Up To: 08-2006 75 PS-90 PS