Ford Galaxy / Ford S-MAX. Manual — part 403

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, Emission Requirements:
Stage IV, 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, Emission Requirements:
Stage IV, 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, Emission Requirements:
Stage IV, 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, Emission Requirements:
Stage IV, 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

(303-04E

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, Emission Requirements:
Stage IV, 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

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, Emission Requirements:
Stage IV, Removal and Installation).
TEST the system for normal operation.