Ford Galaxy / Ford S-MAX. Manual — part 402

Fuel Charging and Controls -
Turbocharger - 2.2L Duratorq-TDCi
(129kW/175PS) - DW - Turbocharger

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

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

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

Chart.

Symptom Chart

Symptom Chart

Pinpoint Tests

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, Emission Requirements:
Stage IV, 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

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