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Diagnosis and Testing|Removal and Installation > < Turbocharger

Mondeo 1997 (08.1996-09.2000)

Fuel Charging and Controls - Turbocharger - Turbocharger Mondeo 1997 (08/1996-09/2000)
Diagnosis and Testing

Special Tool(s)

Boost Pressure Gauge

310 - 020 (23 - 021)

Hand Vacuum/Pressure Pump

416 - D001 (23 - 036A)

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
  • Air cleaner outlet pipe
  • Air cleaner intake pipe
  • Turbocharger oil supply or oil return tube
  • Wastegate control valve
  • Turbocharger housing
  • Turbocharger to fuel injection pump pressure line
  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
*
Wastegate control valve.
*
Turbocharger to fuel injection pump pressure line.
*
CHECK all pressure line(s) are installed and no signs of air leaks are present. REPAIR as necessary.
*
Wastegate control valve.
*
The turbocharger boost pressure is factory set and must not be adjusted. CHECK the paint seal on the wastegate control valve rod has not been broken. If the paint seal has been broken, INSTALL a new turbocharger.
REFER to Turbocharger in this section.
*
Turbocharger to fuel injection pump pressure line.
*
Wastegate control valve pipe blocked or split.
*
Boost pressure incorrect.
*
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
Disconnect the air cleaner outlet pipe from the turbocharger.

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?
Yes
GO TO Fuel Charging and Controls for further blue smoke diagnostics. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
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.

Is there any signs of blockage?
Yes
INSTALL a new oil supply tube. INSTALL a new turbocharger.
REFER to Turbocharger in this section.
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 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 pipe OK?
Yes
GO TO Fuel Charging and Controls for further blue smoke diagnostics. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls.
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 TURBOCHARGER TO FUEL INJECTION PUMP PRESSURE LINE FOR BLOCKAGE
1
Disconnect the turbocharger to fuel injection pump pressure line from the fuel injection pump.
2
Install the special tool to the turbocharger to fuel injection pump pressure line.
3
Using the special tool, create a pressure in the line.

Does the pressure instantly fall to zero?
Yes
GO to C2.
No
INSTALL a new turbocharger to fuel injection pump pressure line. TEST the system for normal operation.
C2: CHECK THE TURBOCHARGER TO FUEL INJECTION PUMP PRESSURE LINE FOR LEAKS
1
Connect the turbocharger to fuel injection pump pressure line to the fuel injection pump.
2
Disconnect the turbocharger to fuel injection pump pressure line from the turbocharger.
3
Install the special tool to the turbocharger to fuel injection pump pressure line.
4
Using the special tool, create a vacuum in the line.

Does the pump hold a vacuum?
Yes
GO to C4.
No
GO to C3.
C3: CHECK THE TURBOCHARGER TO FUEL INJECTION PUMP PRESSURE LINE FOR DAMAGE
1
INSPECT the turbocharger to fuel injection pump pressure line for damage.

Is the turbocharger to fuel injection pump pressure line cracked or damaged?
Yes
INSTALL a new turbocharger to fuel injection pump pressure line. TEST the system for normal operation.
No
Have the fuel injection pump checked by an appropriate fuel injection specialist agent. INSTALL a new fuel injection pump as required only after the specialist agent checks have been carried out. REFER to Section  303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls / 303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger / 303-04E Fuel Charging and Controls. TEST the system for normal operation.
C4: CHECK THE WASTEGATE CONTROL VALVE PIPE FOR BLOCKAGE
1
Remove the wastegate control valve pipe.
2
Install the special tool to the wastegate control valve pipe.
3
Using the special tool, create a pressure in the line.

Does the pressure instantly fall to zero?
Yes
GO to C5.
No
INSTALL a new turbocharger.
REFER to Turbocharger in this section.
TEST the system for normal operation.
C5: CHECK THE WASTEGATE CONTROL VALVE DIAPHRAGM FOR LEAKS
1
Connect the wastegate control valve pipe to the wastegate control valve.
2
Disconnect the wastegate control valve pipe from the turbocharger.
3
Install the special tool to the wastegate control valve pipe.
4
Using the special tool, create a vacuum in the line.

Does the pump hold a vacuum?
Yes
GO to C7.
No
GO to C6.
C6: CHECK THE WASTEGATE CONTROL VALVE PIPE FOR DAMAGE
1
INSPECT the wastegate control valve pipe for damage.

Is the wastegate control valve pipe cracked or damaged?
Yes
INSTALL a new turbocharger.
REFER to Turbocharger in this section.
TEST the system for normal operation.
No
GO to C7.
C7: 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 piece connector, connect the gauge between the wastegate control valve and the turbocharger.
2
Start and run the engine until normal operating temperature is achieved.
3
Raise the engine speed to 3000 RPM and observe the reading.

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

Diagnosis and Testing|Removal and Installation > < Turbocharger