Ford Falcon. Manual — part 174

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Fuel Charging and Controls — Turbocharger

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DIAGNOSIS AND TESTING

Visual Inspection Chart

Turbocharger

Mechanical

Electrical

Inspection and Verification

Oil leak(s)

Wiring harness

Air cleaner element

Electrical connector(s)

NOTE: It is normal for a small amount of combustion

Air cleaner outlet pipe

PCM

gas to pass into the crankcase. These ’blow-by’

Air cleaner intake pipe

Boost Pressure

gases are scavenged into the air intake system

Turbocharger oil

Sensor

through the positive crankcase ventilation (PCV)

supply or oil return

Wastegate Control

system.

tube

Solenoid

Some engine oil, in the form of a vapour is carried into

Turbocharger coolant

the air intake system with the blow-by gases (this

supply or return tube

engine oil also contributes to valve seat durability).

Wastegate valve and

This means that oil will collect inside the air intake

actuator

components and the turbocharger. This is not an

Turbocharger

indication that the turbocharger oil seal has failed. The

housings

turbocharger oil seal will not fail unless the bearings

Turbocharger rotor

fail first, which will cause the turbocharger to become

blades

noisy or seize.

Charge Air Cooler

Ducting to and from

Do not install a new turbocharger due to oil inside the

the Charge Air Cooler

turbocharger or the air intake components. If a leak is

detected in the oil supply or return tubes or

3. If an obvious cause for an observed or reported

connections, locate and rectify the source. Do not

concern is found, correct the cause (if possible)

install a new turbocharger due to an oil leak.

before proceeding to the next step.

1. Verify the customer concern.

4. If the cause is not visually evident, verify the

2. Visually inspect for the following obvious signs of

symptom and refer to Symptom Chart.

mechanical and electrical damage:

or renewed.

Symptom Chart

NOTE: The wastegate actuator diaphragm unit is a

fixed part of the turbocharger and cannot be adjusted

Condition

Source

Action

Blue smoke with excessive

Turbocharger compressor rubbing on

Go to PinPoint Test A.

housing walls.

turbocharger noise

Turbocharger turbine rubbing on
housing walls.
Turbocharger bearings and oil seal(s)
damaged.

Excessive turbocharger noise without

Turbocharger oil supply tube blocked

Go to PinPoint Test A.

blue smoke

or damaged.

Blue smoke without excessive

Turbocharger oil return tube blocked or

Go to PinPoint Test B.

turbocharger noise

damaged.

Wastegate control valve vacuum

CHECK all vacuum line(s) are installed

Poor

engine

performance

and no signs of air leaks are present.

line(s).

REPAIR as necessary.

Unauthorized adjustment of the

The turbocharger boost pressure is

factory set and must not be adjusted.

wastegate control valve actuator rod.

CHECK that the wastegate actuator
valve and rod have not been tampered
with. If there is evidence of tampering,
INSTALL a new turbocharger. REFER
to Removal and Installation -
Turbocharger

CHECK the wastegate valve actuator

Wastegate valve actuator rod.

rod moves freely. If the wastegate
valve actuator rod does not move
freely. CHECK for signs of damage or
signs of foreign material. REPAIR as
necessary. Go to PinPoint Test C

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Fuel Charging and Controls — Turbocharger

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DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests

PINPOINT TEST A : NOISY TURBOCHARGER WITH BLACK OR BLUE EXHAUST SMOKE

Test Step

Result / Action to Take

A1

INSPECT THE TURBOCHARGER COMPRESSOR VANES

FOR DAMAGE

Disconnect the fresh air supply duct from the turbocharger.

Yes

Go to A2

Inspect the compressor rotor vanes for damage.

No

Go to A3

Is there visible damage to the rotor vanes?

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Fuel Charging and Controls — Turbocharger

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DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

A2

CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR

SYSTEM COMPONENTS

Check the intake air system components for signs of foreign material.

Yes

CLEAN the intake air system components.
INSTALL a new turbocharger.
REFER to Removal and Installation -
Turbocharger.

No

Go to A4

Are there any signs of foreign material?

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Fuel Charging and Controls — Turbocharger

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DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

A3

CHECK THE TURBOCHARGER BEARINGS FOR

EXCESSIVE MOVEMENT

Yes

NOTE:

A small amount of movement in the bearings is normal.

Go to A4

Make sure the turbocharger rotor spins freely within the housing.

No

While slowly turning the rotor assembly by hand, push the shaft

INSTALL a new turbocharger.

radially and axially.

REFER to Removal and Installation -
Turbocharger.
TEST the system for normal operation.

Does the rotor spin freely within the housing?

A4

CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR

BLOCKAGE

Yes

NOTE:

New sealing washers should be installed when refitting the oil

INSTALL a new turbocharger oil supply pipe

pipe.

and/or banjo bolt.
INSTALL a new turbocharger.

Disconnect the oil supply tube from the turbocharger.

REFER to Removal and Installation -

Attach a small piece of known good hose to the oil supply tube and

Turbocharger

gently blow down the hose.

TEST the system for normal operation.

INSPECT the banjo bolt and turbo oil gallery for signs of blockage or

No

oil clotting.

Go to A5

Are there any signs of blockage?

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