Ford Galaxy / Ford S-MAX. Manual — part 393

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

S-MAX/Galaxy 2006.5 (02/2006-)

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Diagnosis and Testing

Special Tool(s)

General Equipment

Principles of Operation

The turbocharger is governed by a wastegate control valve. The wastegate control valve
redirects some of the exhaust gas past the turbine and therefore acts as a governor. The
wastegate control valve is preset during manufacture and must not be tampered with.

The intake air system is fitted with a turbocharger pressure release valve. This vents the
intake air system when the throttle is closed and recirculates the air back into the intake air
system. It also releases pressure on the turbocharger which will reduce turbo lag and will
improve acceleration and increase engine performance.

The turbocharger is equipped with a boost control system. The powertrain control module
(PCM) detects 1st or 2nd gear using the engine speed and vehicle speed signals. This
information is then used to adjust the pressures applied to the wastegate control valve
allowing it to open at a lower boost pressure. This prevents the turbocharger developing
maximum boost in 1st and 2nd gears.

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 crankcase vent 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

Boost Pressure Gauge

310-020 (23-021)

Hand Vacuum/Pressure Pump

416-D001 (23-036A)

Ford diagnostic equipment

Mechanical

Electrical

Oil leak(s)
Coolant leak(s)

Wiring harness(es)
Electrical connector(s)

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 concern is not visually evident, verify the symptom and refer to the

Diagnostic Trouble Code (DTC) Index.

Diagnostic Trouble Code (DTC) Index

Symptom Chart

Wastegate control valve
Wastegate control valve vacuum hose(s)
Turbocharger housing
Air cleaner element
Air cleaner outlet pipe
Air cleaner intake pipe
Turbocharger intake tube
Charge air cooler
Charge air cooler intake pipe and hoses
Charge air cooler outlet pipe and hoses
Charge air cooler radiator
Valve cover oil separator
Turbocharger oil supply tube
Turbocharger oil return tube

Charge air cooler cooling fan
Charge air cooler cooling fan switch
Charge air cooler water pump
Boost control solenoid valve
Powertrain control module (PCM)

DTC

Description

Possible Source

Action

P0236

Turbocharger boost pressure

sensor circuit range/performance

concern

Turbocharger boost

pressure sensor

REFER to engine management

guided diagnostics within the

Ford diagnostic equipment.

P0237

Turbocharger boost pressure

sensor circuit low input

Turbocharger boost

pressure sensor

circuit

REFER to engine management

guided diagnostics within the

Ford diagnostic equipment.

P0238

Turbocharger boost pressure

sensor circuit high input

Turbocharger boost

pressure sensor

circuit

REFER to engine management

guided diagnostics within the

Ford diagnostic equipment.

P0243

Turbocharger boost control

solenoid concern

Turbocharger boost

control solenoid

REFER to engine management

diagnostics within the Ford

diagnostic equipment.

NOTE: The wastegate control valve 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

Blocked or damaged

valve cover oil
separator.

*

REFER to:

Engine Emission Control

(303-08B

Engine Emission Control - 2.5L Duratec
(162kW/220PS) - VI5, Diagnosis and Testing).

*

Turbocharger oil

return tube blocked or
damaged.

*

GO to Pinpoint Test

B.

*

Pinpoint Tests

Poor engine
performance

Wastegate control

valve actuator rod.

Vacuum line(s).

*

*

GO to Pinpoint Test

C.

*

Charge air cooler

pipes

Charge air cooler

radiator

Charge air cooler

water pump

Charge air cooler

*

*

*

*

REFER to

in this section.

*

Air cleaner intake

pipe

*

CHECK the air cleaner intake pipe for

obstruction. REPAIR as necessary.

*

Turbocharger boost

pressure

*

GO to Pinpoint Test

C.

*

Unauthorized

adjustment of the
wastegate control
valve actuator rod.

*

The turbocharger boost pressure is factory set

and must not be adjusted. CHECK the paint seal
on the wastegate control valve unit actuator rod
has not been broken. If the paint seal has been
broken, INSTALL a new turbocharger.
REFER to:

Turbocharger

(303-04H Fuel Charging

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

*

Ignition system.

*

CHECK the ignition system.

REFER to:

Fuel Charging and Controls

(303-04C

Fuel Charging and Controls - 2.5L Duratec
(162kW/220PS) - VI5, Diagnosis and Testing).

*

Fuel charging system.

*

CHECK the fuel charging system.

REFER to:

Fuel Charging and Controls

(303-04C

Fuel Charging and Controls - 2.5L Duratec
(162kW/220PS) - VI5, Diagnosis and Testing).

*

PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE

Remove the air cleaner.
REFER to:

Air Cleaner

(303-12C Intake Air

Distribution and Filtering - 2.5L Duratec
(162kW/220PS) - VI5, Removal and Installation).

1

Inspect the turbocharger rotor vanes for damage.

2

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

1

of foreign material.

Are there any signs of foreign material?
Yes

CLEAN the intake air system components. 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

GO to A3

.

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 without
excessive movement?
Yes

GO to A4

.

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.

A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE

NOTE: Discard the copper washers.

Disconnect the oil supply tube from the
turbocharger (exhaust manifold heatshield and

charge air cooler intake pipe shown removed for
clarity).

1

NOTE: Discard the copper washers.

Disconnect the oil supply tube from the engine and
remove the oil supply tube.

2

Using workshop compressed air and a compressed
air nozzle check the oil supply tube for blockage.

3

Is the oil supply tube free from blockage?
Yes