Ford Galaxy / Ford S-MAX. Manual — part 397

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

(303-04I Fuel Charging and

Controls - Turbocharger - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, 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

(303-04I Fuel Charging and

Controls - Turbocharger - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Removal and Installation).
TEST the system for normal operation.

A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE

Remove the turbocharger.
REFER to:

Turbocharger

(303-04I Fuel Charging and

Controls - Turbocharger - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Removal and Installation).

1

Using workshop compressed air and a compressed

2

air nozzle, check the oil supply tube for blockage.

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

(303-04I Fuel Charging and

Controls - Turbocharger - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Removal and Installation).
TEST the system for normal operation.

A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE

Visually inspect the oil supply tube oil gallery for
blockage.

1

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

INSTALL a new turbocharger and oil supply pipe.
REFER to:

Turbocharger

(303-04I Fuel Charging and

Controls - Turbocharger - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Removal and Installation).
TEST the system for normal operation.

No

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

Turbocharger

(303-04I Fuel Charging and

Controls - Turbocharger - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, 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.

2

NOTE: Discard the gasket(s).

Remove the turbocharger oil return pipe.

3

Check the turbocharger oil return pipe for 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

(303-04D

Fuel Charging and Controls - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Diagnosis and Testing).

No

INSTALL a new turbocharger oil return pipe. TEST
the system for normal operation.

Fuel Charging and Controls - Turbocharger -
1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) -
Lynx - Turbocharger

S-MAX/Galaxy 2006.5 (02/2006

Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

Installation

1. Remove the following items:

Refer to:

Catalytic Converter

(309-00D Exhaust

System - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Removal and Installation).
Refer to:

Air Cleaner

(303-12D Intake Air

Distribution and Filtering - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Removal and Installation).

2.

NOTE: Note the position of the component before
removal.

Discard the clamp.

3.

3. Discard the nut.

4. Discard the oil supply tube.

1.

NOTE: Make sure that a new component is installed.

Torque:

35 Nm