Ford Galaxy / Ford S-MAX. Manual — part 399
(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
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
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
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