Ford Galaxy / Ford S-MAX. Manual — part 394

GO to A5

.

No

INSTALL a new oil supply tube. INSTALL a new
turbocharger.
REFER to:

Turbocharger

(303-04H Fuel Charging

and Controls - Turbocharger - 2.5L Duratec
(162kW/220PS) - VI5, Removal and Installation).
TEST the system for normal operation.

A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY

Using some suitable welding rod check the oil
supply tube oil gallery for blockage.

1

Is the oil supply tube oil gallery free from blockage?
Yes

INSTALL a new turbocharger.
REFER to:

Turbocharger

(303-04H Fuel Charging

and Controls - Turbocharger - 2.5L Duratec
(162kW/220PS) - VI5, Removal and Installation).
TEST the system for normal operation.

No

REMOVE the blockage. INSTALL a new
turbocharger.
REFER to:

Turbocharger

(303-04H Fuel Charging

and Controls - Turbocharger - 2.5L Duratec
(162kW/220PS) - VI5, 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

NOTE: Discard the gasket.

Disconnect the turbocharger oil return tube from
the turbocharger (turbocharger heatshield and

catalytic converter shown removed for clarity).

1

NOTE: Discard the O-ring seal.

Remove the turbocharger oil return tube
(turbocharger heatshield and catalytic converter

shown removed for clarity).

2

Check the turbocharger oil return tube for blockage
or signs of damage.

3

Is the turbocharger oil return tube free from foreign
material and signs of damage?
Yes

GO to Engine for further diagnostics.
REFER to:

Engine

(303-01D Engine - 2.5L Duratec

(162kW/220PS) - VI5, Diagnosis and Testing).

No

INSTALL a new turbocharger oil return pipe, gasket
and O-ring seal. TEST the system for normal
operation.

PINPOINT TEST C : POOR ENGINE PERFORMANCE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK THE BOOST PRESSURE

NOTE: The boost pressure is factory set and must not be adjusted.
This test must be carried out on a length of road with a minimum speed limit of 100kmh
(60mph).

Disconnect the wastegate control valve actuator
control pipe from the wastegate control valve

actuator.

1

Connect a suitable length of pipe to the wastegate
control valve actuator.

2

Using the boost pressure gauge and T connector,
connect the gauge to the length of pipe.

3

Connect the wastegate control valve actuator
control pipe to the T connector.

4

NOTE: Make sure the boost pressure gauge pipe
does not become kinked or trapped.

Route the boost pressure gauge and pipe into the
vehicle through the passenger window.

5

With the aid of another technician carry out a
roadtest.

6

Raise the vehicle speed to 60kmh (40mph).

7

Select third gear.

8

NOTE: Do not exceed the road speed limit.

Apply wide open throttle until a speed of 100kmh
(60mph) is reached.

9

Is a boost pressure reading of 201 KPa displayed?
Yes

REFER to

in this section.

No

GO to C2

.

C2: CHECK THE OPERATION OF THE WASTEGATE CONTROL VALVE

Disconnect the wastegate control valve actuator
control pipe from the T connector.

1

Connect the hand vacuum/pressure pump to the T
connector.

2

Operate the hand vacuum/pressure pump until a
reading of 75 ± 4 KPa is shown on the boost

pressure gauge.

3

Measure the movement of the wastegate control
valve actuator rod.

4

Does the wastegate control valve actuator rod move
10mm and then return to the rest position when the
pressure is released?
Yes

REFER to the Ford diagnostic equipment.

No

INSTALL a new turbocharger.
REFER to:

Turbocharger

(303-04H Fuel Charging

and Controls - Turbocharger - 2.5L Duratec
(162kW/220PS) - VI5, Removal and Installation).
TEST the system for normal operation.