Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) - DW - Turbocharger
Mondeo 2007.5 (02/2007-)
Print
Diagnosis and Testing
Special Tool(s)
General Equipment
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.
1.
1. Verify the customer concern.
2.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
3.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4.
4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Pinpoint Tests
Hand Vacuum/Pressure Pump
416 - D001 (23 - 036A)
Fuel Pressure Gauge
310-053 (23-046)
Worldwide Diagnostic System (WDS) (418-
F224)
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
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
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-
TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, 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.
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CONDITIONS
DETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove the engine upper cover.
1
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Disconnect the positive crankcase ventilation (PCV) breather hose from the intake manifold PCV valve.
Press in the release clip.
2
Remove the turbocharger intake pipe support bracket retaining bolt.
3
Raise and support the vehicle. For additional information,
REFER to:
Lifting
(100-02 Jacking and Lifting, Description and Operation).
4
Remove the engine undershield.
Rotate the locking tangs counterclockwise.
5
Detach the turbocharger intake pipe.
6
Inspect the turbocharger rotor vanes for damage.
7
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
Check the intake air system components for signs of foreign material.
1
Are there any signs of foreign material?
Yes
CLEAN the intake air system components. INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
No
GO to A4
.
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE: A small amount of movement in the bearings is normal.
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.
1
Does the rotor spin freely within the housing with no excessive movement?
Yes
GO to A4
.
No
INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE: Discard the copper washers.
Remove the turbocharger oil supply tube.
1
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Using workshop compressed air and a compressed air nozzle, check the oil supply tube for blockage.
2
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
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
Using a suitable welding filler rod, check the oil supply tube oil gallery for blockage.
1
Is the oil supply tube oil gallery free from blockage?
Yes
GO to A6
.
No
REMOVE the blockage. INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
A6: CHECK THE TURBOCHARGER OIL SUPPLY TUBE NON RETURN VALVE FOR CORRECT OPERATION AND BLOCKAGE
Remove the turbocharger oil supply pipe union non return valve.
1
Inspect the turbocharger oil supply pipe union for blockage.
2
Is the oil supply pipe union non return valve free to move and the union free from blockage?
Yes
INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
No
INSTALL a new turbocharger and oil supply pipe non return valve.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, 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
Raise and support the vehicle. For additional information,
REFER to:
Lifting
(100-02 Jacking and Lifting, Description and Operation).
1
Remove the engine undershield.
Rotate the locking tangs counterclockwise.
2
NOTE: Discard the gasket.
Remove the turbocharger oil return pipe.
3
Check the turbocharger oil return pipe for a blockage or signs of damage.
4
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
(303-04F Fuel Charging and Controls - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Diagnosis and Testing).
No
INSTALL a new turbocharger oil return pipe. TEST the system for normal operation.
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TEST CONDITIONS
DETAILS/RESULTS/ACTIONS
C1: CHECK THE VACUUM CONTROL CIRCUIT FOR VACUUM
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Disconnect the vacuum line from the turbocharger vacuum control solenoid.
1
Install the special tool between the turbocharger vacuum control solenoid and vacuum line.
2
Start and run the engine.
3
With the engine at idle does the special tool indicate a vacuum of 0.325 bar or above?
Yes
GO to C2
.
No
GO to C4
.
C2: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT
Ignition switch in position 0.
1
Raise and support the vehicle. For additional information,
REFER to:
Lifting
(100-02 Jacking and Lifting, Description and Operation).
2
Remove the engine undershield.
Rotate the locking tangs counterclockwise.
3
Disconnect the vacuum line from the vane adjustment diaphragm unit.
4
Install the special tool to the vane adjustment diaphragm unit.
5
Operate the special tool until a vacuum of 35 Kpa is achieved. Measure the distance travelled by the vane adjustment
diaphragm unit actuator rod.
6
Does the vane adjustment diaphragm unit actuator rod move between 9 and 11 mm?
Yes
GO to C3
.
No
CHECK for signs of damage or signs of foreign material in the turbocharger vanes. INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
C3: CHECK THE TURBOCHARGER BOOST PRESSURE
Remove special tool 416-D001.
1
Connect the vacuum line to the vane adjustment diaphragm unit.
2
Lower the vehicle.
3
Connect WDS to the vehicle data link connector (DLC).
4
Select the dataloger function.
5
Configure dataloger to read the intake manifold pressure via the manifold absolute pressure (MAP) sensor.
6
Start and run the engine.
7
With the aid of another Technician, raise the engine speed to 2000 rpm.
8
Observe the readings of special tool 310-053 and the WDS manifold pressure display.
9
Is a vacuum of 0.325 bar on the special tool and boost pressure of 1.5 bar on the WDS manifold pressure display
indicated?
Yes
Continue the diagnostic of the engine management system using WDS.
No
INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS
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Ignition switch in position 0.
1
Remove the special tool 310-053.
2
Install the special tool to the vacuum diaphragm unit vacuum line.
3
Operate the special tool and observe the reading.
4
Does the special tool hold vacuum?
Yes
GO to C5
.
No
GO to C6
.
C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE
Disconnect Turbocharger vain adjustment solenoid C585.
1
Start and run the engine.
2
Measure the voltage between C585 pin 1, circuit 15S-RL50 (GN/BU) harness side and C585 pin 2, circuit 91S-RL50
(BK/BU) harness side.
3
With the engine at idle, is the voltage greater than 10 volts?
Yes
INSTALL a new turbocharger vacuum control solenoid. TEST the system for normal operation.
No
Continue the diagnostic of the engine management system using WDS.
C6: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS
Raise and support the vehicle. For additional information,
REFER to:
Lifting
(100-02 Jacking and Lifting, Description and Operation).
1
Remove the engine undershield.
Rotate the locking tangs counterclockwise.
2
Disconnect the vacuum line from the vacuum diaphragm unit.
3
Install the special tool to the vane adjustment diaphragm unit.
4
Operate the special tool and observe the reading.
5
Does the special tool hold vacuum?
Yes
INSTALL a new vacuum line. TEST the system for normal operation.
No
INSTALL a new turbocharger.
REFER to:
Turbocharger
(303-04J Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-TDCi (85kW/115PS) -
DW/2.0L Duratorq-TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi (103kW/140PS) - DW, Removal and Installation).
TEST the system for normal operation.
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