Ford Galaxy / Ford S-MAX. Manual — part 400

Inspect the turbocharger oil supply pipe union for
blockage.

2

Is the oil supply pipe union non return valve free to
move and the union free from blockage?
Yes

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

INSTALL a new turbocharger and oil supply pipe
non return valve.
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.

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.

Rotate the locking tangs counterclockwise.

2

NOTE: Discard the gasket.

Remove the turbocharger oil return pipe.

3

Check the turbocharger oil return pipe for a
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

(303-04E

Fuel Charging and Controls - 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, Diagnosis and Testing).

No

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

PINPOINT TEST C : POOR ENGINE PERFORMANCE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK THE VACUUM CONTROL CIRCUIT FOR VACUUM

Disconnect the vacuum line from the turbocharger
vacuum control solenoid.

1

Install the special tool between the turbocharger
vacuum control solenoid and vacuum line.

2

Start and run the engine.

3

With the engine at idle does the special tool indicate a
vacuum of 0.325 bar or above?
Yes

GO to C2

.

No

GO to C4

.

C2: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT

Ignition switch in position 0.

1

Raise and support the vehicle. For additional
information,

REFER to:

Lifting

(100-02 Jacking and Lifting,

Description and Operation).

2

Remove the engine undershield.

Rotate the locking tangs counterclockwise.

3

Disconnect the vacuum line from the vane
adjustment diaphragm unit.

4

Install the special tool to the vane adjustment
diaphragm unit.

5

Operate the special tool until a vacuum of 35 Kpa
is achieved. Measure the distance travelled by the

vane adjustment diaphragm unit actuator rod.

6

Does the vane adjustment diaphragm unit actuator rod
move between 9 and 11 mm?
Yes

GO to C3

.

No

CHECK for signs of damage or signs of foreign
material in the turbocharger vanes. 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.

C3: CHECK THE TURBOCHARGER BOOST PRESSURE

Remove special tool 416-D001.

1

Connect the vacuum line to the vane adjustment
diaphragm unit.

2

Lower the vehicle.

3

Connect WDS to the vehicle data link connector
(DLC).

4

Select the dataloger function.

5

Configure dataloger to read the intake manifold
pressure via the manifold absolute pressure (MAP)

sensor.

6

Start and run the engine.

7

With the aid of another Technician, raise the
engine speed to 2000 rpm.

8

Observe the readings of special tool 310-053 and
the WDS manifold pressure display.

9

Is a vacuum of 0.325 bar on the special tool and boost
pressure of 1.5 bar on the WDS manifold pressure
display indicated?
Yes

Continue the diagnostic of the engine management
system using WDS.

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.

C4: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR LEAKS

Ignition switch in position 0.

1

Remove the special tool 310-053.

2

Install the special tool to the vacuum diaphragm
unit vacuum line.

3

Operate the special tool and observe the reading.

4

Does the special tool hold vacuum?
Yes

GO to C5

.

No

GO to C6

.

C5: CHECK THE TURBOCHARGER VANE ADJUSTMENT SOLENOID VALVE DUTY CYCLE

Disconnect Turbocharger vain adjustment solenoid
C585.

1

Start and run the engine.

2

Measure the voltage between C585 pin 1, circuit
15S-RL50 (GN/BU) harness side and C585 pin 2,

circuit 91S-RL50 (BK/BU) harness side.

3