| Diagnosis and Testing Special Tool(s) | | Hand Vacuum/Pressure Pump 416 - D001 (23 - 036A) | 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 vapour 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 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
- Vacuum diaphragm unit - vehicles with variable vane turbocharger
- Wastegate control valve - vehicles with fixed vane turbocharger
- Turbocharger
- Charge air cooler
| | - 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 serviced separately. NOTE:The wastegate control valve is a fixed part of the turbocharger and cannot be adjusted or serviced 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. | * | | Blue smoke without excessive turbocharger noise | * Turbocharger oil return tube blocked or damaged. | * | | Poor engine performance | * Vacuum diaphragm unit vacuum line(s) - vehicles with variable vane turbocharger. | * CHECK all vacuum line(s) are installed and no signs of air leaks are present. REPAIR as necessary. | | * Unauthorized adjustment of the vacuum diaphragm unit actuator rod - vehicles with variable vane turbocharger. | * The vacuum diaphragm unit actuator rod 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 - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| | * Vacuum diaphragm unit actuator rod - vehicles with variable vane turbocharger. | * 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. * | | * Wastegate control valve line(s) - vehicles with fixed vane turbocharger. | * CHECK all line(s) are installed and no signs of air leaks are present. REPAIR as necessary. | | * Unauthorized adjustment of the wastegate control valve actuator rod - vehicles with fixed vane turbocharger. | * 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 - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| | * Wastegate control valve actuator rod - vehicles with fixed vane turbocharger. | * 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. REPAIR as necessary. * | 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 Detach the turbocharger intake pipe. | | | 2 Inspect the turbocharger rotor vanes for damage. | | | Is there visible damage to the rotor vanes? Yes No | | 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 - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation. No | | A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT | 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 that the rotor spins freely within the housing.
| | | Does the rotor spin freely within the housing with no excessive movement? Yes No INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation. | | A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE | | | 1 Remove the oil supply tube from the turbocharger and the cylinder block. | | | 2 Using workshop compressed air, check the turbocharger oil supply tube for blockage or signs of damage. | | | Are there any signs of blockage or damage? Yes INSTALL a new turbocharger oil supply tube. TEST the system for normal operation. No INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, 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 Remove the turbocharger oil return pipe. | | | 2 Using workshop compressed air, check the turbocharger oil return pipe for blockage or signs of damage. | | | Are there any signs of blockage or damage? Yes INSTALL a new turbocharger oil return pipe. TEST the system for normal operation. No GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
| | PINPOINT TEST C : POOR ENGINE PERFORMANCE - VEHICLES WITH VARIABLE VANE TURBOCHARGER | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | C1: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR BLOCKAGE | | | 1 Disconnect the vacuum diaphragm unit vacuum line at both ends. | | | 2 Block the vacuum line at the vacuum diaphragm unit end. | | | 3 Install the special tool to the other end of the vacuum diaphragm unit vacuum line. | | | 4 Operate the hand vacuum pump and observe the reading. | | | Does the vacuum pump hold a vacuum? Yes No INSTALL a new vacuum diaphragm unit vacuum line. TEST the system for normal operation. | | C2: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS | | | 1 Install the special tool to the vacuum diaphragm unit. | | | 2 Operate the hand vacuum pump and observe the reading. | | | Does the vacuum pump hold a vacuum? Yes No INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation. | | C3: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT | | | 1 Operate the hand vacuum pump until a vacuum of 65 Kpa is achieved. Measure the distance travelled by the vacuum diaphragm unit actuator rod. | | | Does the vacuum diaphragm unit actuator rod move between 9 mm and 11 mm? Yes GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
No CHECK for signs of damage or signs of foreign material in the turbocharger vanes. INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation. | | PINPOINT TEST D : POOR ENGINE PERFORMANCE - VEHICLES WITH FIXED VANE TURBOCHARGER | | TEST CONDITIONS | DETAILS/RESULTS/ACTIONS | | D1: CHECK THE WASTEGATE CONTROL VALVE LINE FOR BLOCKAGE | | | 1 Disconnect the wastegate control valve line at both ends. | | | 2 Block the wastegate control valve line at the wastgate control valve end. | | | 3 Install the special tool to the other end of the wastegate control valve line. | | | 4 Operate the hand vacuum pump and observe the reading. | | | Does the vacuum pump hold a vacuum? Yes No INSTALL a new wastegate control valve line. TEST the system for normal operation. | | D2: CHECK THE WASTEGATE CONTROL VALVE FOR LEAKS | | | 1 Install the special tool to the wastegate control valve. | | | 2 Operate the hand vacuum pump and observe the reading. | | | Does the vacuum pump hold a vacuum? Yes No INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation. | | D3: CHECK THE WASTEGATE CONTROL VALVE ACTUATOR ROD MOVEMENT | | | 1 Operate the hand vacuum pump until a vacuum of 65 Kpa is achieved. Measure the distance travelled by the wastegate control valve actuator rod. | | | Does the wastegate control valve actuator rod move between 9 mm and 11 mm? Yes GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel, Diagnosis and Testing).
No INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation. | |
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40800.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40801.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40804.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E81894.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40803.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40805.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40806.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40807.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E40808.jpg)
 Diesel-1.8L Duratorq-TDCi (Lynx) Diesel-2.0L Duratorq-TDCi (DW) Diesel/Description and Operation/Diagnosis and Testing//img/E81895.jpg)
