Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Moottori, voimansiirto, viritys jne.
-TONI-
Viestit: 3
Liittynyt: 08 Marras 2018 16:43

Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja -TONI- »

Mondeoon iskenyt semmonen vika, että alakierroksilla on vääntö ja tehot aivan hukassa ja pöllyttää mustaa savua melkolailla mutta kun kierrokset nousee sinne liki 2000rpm että alkaa ahtamaan niin sitten kyllä kulkee juuri niinkuin kuuluukin eikä enään juurikaan savutakkaan. Ahtovuodot on tarkastettu ja korjattu eikä kone anna myöskään mitään vikakoodia, tai ainakaan ei tauluun syty vikavaloja.
Onkohan turbossa jotain vikaa vai mitä olette mieltä
Avatar
czr96
Viestit: 114
Liittynyt: 09 Joulu 2013 09:22
Paikkakunta: Oulu

Re: Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja czr96 »

kokeileppas nippaista se musta kumi letku irti EGR venttiilistä...ruuvaa vaikka sopiva ruuvi siihen letkuun ettei imuroi likaa sisään. ja koeajolle... veikkaan että huomaat eron :)

se sytyttää kolmannen startin jälkeen moottorinvikavalon, mutta se on lähinnä kosmeettinen haitta mittaristossa. Lähtee pois ihan perus OBD lukijalla jos on tarvista. näin ainakin voit paikallistaa mahdollisen vikapesäkkeen...
...Luultavasti en tiiä...
Mondeo 2.0 tdci 120kW -11
-TONI-
Viestit: 3
Liittynyt: 08 Marras 2018 16:43

Re: Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja -TONI- »

Egr venttiili on kyllä pari päivää sitten uusittu mutta täytyy kokeilla. Mikäs sen letkun virka siinä niinkuin on?
Tämä ongelma siis alkoi sen jälkeen kun alkuviikosta vaihdoin egr venttiilin ja sen ahtoletkun siitä egr ja coolerin välistä kun oli revennyt. Egr oli varmaan kuukauden päivät rikki/vikatilassa ennenkuin vaihdoin ja ahtoletkunkin oli jo jonkin aikaa suhissut kun ei meinannut vuotoa löytyä millää mutta oli vielä niin pieni vuoto että auto toimi ihan normaalisti että tehoa oli ihan alakierroksilta asti toki ei ihan täysiä ahtanut. Sit tuo ahtoletku repes kunnolla alkuviikosta ja vaihdoin sen ja samalla uuden egr venttiilin ja sit tuli tämä tehon puute ongelma
-TONI-
Viestit: 3
Liittynyt: 08 Marras 2018 16:43

Re: Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja -TONI- »

No ei ole näköjään ihmeiden aika ohitte :D rupes mondeo pelaamaan taas kun tulppas ton egr:ltä lähtevän pikkusen musta letkun. Kiitoksia vaan hyvästä neuvosta, meinasin jo masentua että joutuuko tässä turbo vielä uusimaan :D
Oliko siis niin hyvä tuuri että uusi egr oli jo valmiiksi rikki
Deippa
Viestit: 487
Liittynyt: 02 Touko 2012 11:52
Paikkakunta: P-Pmaa

Re: Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja Deippa »

ei välttämättä. se vaan saattaa nyt oikeesti avautua ja sitä vähemmän raitista ilmaa tulee sinne palotapahtumaan liikaa. Mikäs siinä edellisessä egr:ssä oli vikana?
S-MAX -10 TDCI 140hv
Avatar
czr96
Viestit: 114
Liittynyt: 09 Joulu 2013 09:22
Paikkakunta: Oulu

Re: Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja czr96 »

niin sitä minä vain, että mahtaisko tuo oppia itekseen jos oisit sillä jonkun aikaa ajellut.. että oisko vähän ihmeissään nyt aluksi jonkin aikaa kun kaikki hilut toimiikin nyt yhtäkkiä. parametrit sekaisin...
...Luultavasti en tiiä...
Mondeo 2.0 tdci 120kW -11
Mk3Mondeo
Viestit: 904
Liittynyt: 22 Maalis 2018 17:12

Re: Mondeo mk3 -07 2.0 tdci alaväännöt hukassa

Viesti Kirjoittaja Mk3Mondeo »

-TONI- kirjoitti:No ei ole näköjään ihmeiden aika ohitte :D rupes mondeo pelaamaan taas kun tulppas ton egr:ltä lähtevän pikkusen musta letkun. Kiitoksia vaan hyvästä neuvosta, meinasin jo masentua että joutuuko tässä turbo vielä uusimaan :D
Oliko siis niin hyvä tuuri että uusi egr oli jo valmiiksi rikki
Tarkoitatko turbolle menevää alipaineletkua? Tosin v. 2007 -mallissahan on ilmeisesti sähköohjattu turbon siipien ohjaus mutta vanhemmassa alipaineletkun kytkentä oli turbon alipainekellossa.
Tuota muuttuvasiipisen ohjausta ei kannata muuttaa koska se on suunniteltu toimimaan PCM:n (Power Control Module eli ECU) ohjaamana.

Euro4 eli sähköohjatun eli Actuatorin rikkoutumiset ovat ilmeisesti hyvin yleisiä ja tuota osaa saa hyvin kunnostettuna ebaystä.

https://www.ebay.co.uk/sch/i.html?_from ... l&_sacat=0


Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Turbocharger Mondeo 2001 (10/2000-02/2007)
Diagnosis and Testing

Special Tool(s)



Hand Vacuum/Pressure Pump

416-D001 (23-036A)
General Equipment
Worldwide Diagnostic System (WDS)

Principles of Operation - Vehicles with fixed vane turbocharger

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.

Principles of Operation - Vehicles with variable vane turbocharger

The turbocharger is designed to improve engine induction and engine performance. The list below details the concerns relating to turbocharger performance.

High engine speed produces excessive turbine speed and therefore creates excessive turbocharger boost pressure.
Low engine speed does not produce sufficient turbine speed and therefore not enough turbocharger boost pressure is achieved.

The variable vane turbocharger does not have a wastegate control valve. Instead, it has variable turbocharger vanes which are located in the turbocharger turbine housing. The turbocharger vanes act as the control for the turbocharger boost pressure.

The variable turbocharger produces its full turbocharger boost pressure over the entire engine speed range, not just at high engine speed. This is achieved through the adjustment of the vanes and the resulting change in the velocity of the exhaust gas.

The speed of flow of the stream of exhaust gas is increased independent of engine speed by varying the intake cross section in front of the turbocharger turbine.

The variable vanes are controlled by the PCM. A duty cycle signal from the powertrain control module (PCM), controls a vacuum supply to the turbocharger vacuum diaphragm unit using a solenoid valve.

Regulation at Low Engine Speed


Item
Part Number
Description
1
-
Vane adjustment solenoid valve
2
-
Atmospheric pressure
3
-
Vacuum
4
-
Adjusting ring
5
-
Vanes
6
-
Vanes
7
-
Turbine
8
-
Turbine
9
-
Vacuum diaphragm unit
10
-
PCM

At low engine speeds the PCM actuates the vane adjustment solenoid valve to enable a vacuum to be applied. The vacuum diaphragm unit moves the adjusting ring so that the vanes are set at a shallow angle. The reduced intake cross section this creates for the stream of exhaust gas increases the exhaust gas velocity allowing the turbocharger boost pressure to build up rapidly and easily at low engine speeds.

Regulation at Moderate Engine Speed


Item
Part Number
Description
1
-
Vane adjustment solenoid valve
2
-
Atmospheric pressure
3
-
Vacuum
4
-
Adjusting ring
5
-
Vanes
6
-
Vanes
7
-
Turbine
8
-
Turbine
9
-
Vacuum diaphragm unit
10
-
PCM

As the engine speed increases and the quantity of exhaust gas increases as a result, the vane adjustment solenoid valve adjusts the vacuum level within the vacuum diaphragm unit. The vacuum diaphragm unit moves the adjusting ring so that the vanes are set at a steeper angle. The steeper angle opens the intake cross section effectively reducing the gas flow and turbine speed while maintaining constant turbocharger boost pressure.

Regulation at Maximum Engine Speed


Item
Part Number
Description
1
-
Vane adjustment solenoid valve
2
-
Atmospheric pressure
3
-
Vacuum
4
-
Adjusting ring
5
-
Vanes
6
-
Vanes
7
-
Turbine
8
-
Turbine
9
-
Vacuum diaphragm unit
10
-
PCM

As the engine speed increases the intake cross section in front of the turbocharger turbine is continuously enlarged. The turbine speed and hence the quantity of the air supplied to the engine, is adjusted to suit the engine speed. This means that the turbocharger boost pressure remains optimized over all engine speeds.

The maximum position of the turbocharger vanes (maximum opening cross section) is also an emergency position e.g. in the event of an electrical concern or leak in the vacuum system. Therefore, there is little chance of engine damage due to excessive boost in the event of a turbocharger control concern.

Inspection and Verification
NOTE:
NOTE:The turbocharger uses engine oil as a lubricant and coolant. Due to the high operating temperatures of the turbocharger and with the expansion and contraction of the internal components a proportion of engine oil may enter the air intake system. 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. Do not install a new turbocharger due to oil inside the turbocharger or the air intake components. If a leak is detected in the supply or return tubes or connections, locate and rectify the source. Do not install a new turbocharger due to an oil leak.

Verify the customer concern.

Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart
Mechanical Electrical

Oil leak(s)
Air cleaner element
Air cleaner outlet pipe
Air cleaner intake pipe
Turbocharger oil supply tube
Turbocharger oil return tube
Vacuum line(s) - vehicles with variable vane turbocharger
Vacuum diaphragm unit - vehicles with variable vane turbocharger
Wastegate control valve - vehicles with fixed vane turbocharger
Turbocharger housing
Charge air cooler
Charger air cooler intake pipe
Charger air cooler outlet pipe



Wiring harness
Electrical connector(s)
Vane adjustment solenoid valve
Turbocharger electric actuator
PCM

If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.

If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart
CAUTION:
CAUTION:The turbocharger electric actuator must not be transferred between the old and new turbochargers. Failure to follow this instruction may result in incorrect calibration, exhaust emissions and engine operation.
NOTE:
NOTE:On vehicles with variable vane turbocharger the vacuum diaphragm unit and actuator rod are fixed parts of the turbocharger and cannot be adjusted or renewed.

Symptom Chart
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.

*
All except vehicles with variable vane electric actuator, GO to Pinpoint Test A.
*
Vehicles with variable vane electric actuator, GO to Pinpoint Test B.
Blue smoke without excessive turbocharger noise
*
Turbocharger oil return tube blocked or damaged.

*
GO to Pinpoint Test C.
Poor engine performance
*
Charge air cooler system.

*
CHECK the charge air cooler, charge air cooler pipe(s) for leaks and obstructions. REPAIR as necessary.
*
Air cleaner intake pipe.

*
CHECK the air cleaner intake pipe for obstructions. REPAIR as necessary.
*
Vacuum diaphragm unit vacuum line(s) - vehicles with variable vane turbocharger.

*
CHECK all vacuum line(s) are installed and no signs of air leaks are present. REPAIR as necessary.
*
Unauthorized adjustment of the vacuum diaphragm unit actuator rod - vehicles with variable vane turbocharger.

*
The turbocharger vacuum diaphragm unit actuator rod 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 - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
*
Unauthorized adjustment of the wastegate control valve actuator rod - vehicles with fixed vane turbocharger.

*
The wastegate control valve actuator rod is factory set and must not be adjusted. CHECK the paint seal on the wastegate control valve actuator rod has not been broken. If the paint seal has been broken, INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
*
Vacuum diaphragm unit actuator rod - vehicles with variable vane turbocharger.

*
Using WDS, obtain the diagnostic trouble codes (DTCs). Run the exhaust gas recirculation (EGR) test and manifold absolute pressure (MAP) test from the guided diagnostic routines. If no faults are found, GO to Pinpoint Test D.
*
Wastegate control valve actuator rod - vehicles with fixed vane turbocharger.

*
GO to Pinpoint Test E.
*
Turbocharger electric actuator.

*
REFER to WDS.

Pinpoint Tests

PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE - ALL EXCEPT VEHICLES WITH VARIABLE VANE ELECTRIC ACTUATOR
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE


1
Remove the engine cover.

2
Disconnect the air cleaner outlet pipe from the turbocharger.


3
Inspect the turbocharger rotor vanes for damage.


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

1
Check the intake air system components for signs of foreign material.


Are there any signs of foreign material?
Yes
CLEAN the intake air system components. INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
No
GO to A4.
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:
NOTE:A small amount of movement in the bearings is normal.
NOTE:
NOTE:The initial rotor rotation of a cold turbocharger may feel rough and uneven but should rotate freely after a few turns.


1
Make sure that 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 that the rotor spins freely within the housing.


Does the rotor spin freely within the housing?
Yes
GO to A4.
No
INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE:
NOTE:On vehicles built 07/2004 onwards, the sealing washers cannot be removed from the turbocharger oil supply tube. On vehicles built up to 07/2004, discard the sealing washers


1
Remove the turbocharger oil supply tube.

2
Using workshop compressed air and a compressed air nozzle, check the oil supply tube for blockage.


Is there any signs of blockage?
Yes
GO to A5.
No
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE

1
Visually inspect the oil supply tube oil gallery in the cylinder block for blockage.


Is the oil supply tube oil gallery free from blockage?
Yes
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
No
REMOVE the blockage. INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.

PINPOINT TEST B : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE - VEHICLES WITH VARIABLE VANE ELECTRIC ACTUATOR
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
B1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE


1
Remove the engine cover.


2
Disconnect the turbocharger intake pipe.


3
Inspect the turbocharger rotor vanes for damage.


Is there visible damage to the rotor vanes?
Yes
GO to B2.
No
GO to B3.
B2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS

1
Check the intake air system components for signs of foreign material.


Are there any signs of foreign material?
Yes
CLEAN the intake air system components. INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
or
REFER to: Turbocharger - Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
No
GO to B4.
B3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:
NOTE:A small amount of movement in the bearings is normal.
NOTE:
NOTE:The initial rotor rotation of a cold turbocharger may feel rough and uneven but should rotate freely after a few turns.


1
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.


Does the rotor spin freely within the housing?
Yes
GO to B4.
No
INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
or
REFER to: Turbocharger - Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
B4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE

1
Remove the turbocharger.
REFER to: Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
or
REFER to: Turbocharger - Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).

2
Using workshop compressed air and a compressed air nozzle, check the oil supply tube for blockage.


Is the oil supply tube free from blockage?
Yes
GO to B5.
No
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
or
REFER to: Turbocharger - Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
B5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE

1
Visually inspect the oil supply tube oil gallery in the cylinder block for blockage.


Is the oil supply tube oil gallery free from blockage?
Yes
INSTALL a new turbocharger and turbocharger oil supply tube.
REFER to: Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
or
REFER to: Turbocharger - Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.
No
REMOVE the blockage. INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles Built Up To: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
or
REFER to: Turbocharger - Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.

PINPOINT TEST C : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
C1: CHECK THE TURBOCHARGER OIL RETURN TUBE


1
Remove the engine undershield.


2
Disconnect the turbocharger oil return tube from the turbocharger (catalytic converter shown removed for clarity).


3
Remove the turbocharger oil return tube.

4
Check the turbocharger oil return tube for a blockage or signs of damage.


Is the turbocharger oil return tube OK?
Yes
GO to Fuel Charging and Controls for further blue smoke diagnostics.
REFER to: Fuel Charging and Controls (303-04C Fuel Charging and Controls - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Diagnosis and Testing).
No
INSTALL a new turbocharger oil return tube. TEST the system for normal operation.

PINPOINT TEST D : POOR ENGINE PERFORMANCE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
D1: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT

1
Start the engine.


2
Observe the vane control lever.


Does the diaphragm actuator rod travel its maximum distance and the vane control lever reach its stop?
Yes
GO to D2.
No
GO to D3.
D2: CHECK THE TURBOCHARGER BOOST PRESSURE

1
Stop the engine.


2
Disconnect the vacuum line from the vacuum diaphragm unit.


3
Install the special tool to the vacuum diaphragm unit.

4
Using WDS datalogger, PCM function, select the signals for RPM# and MAP.

5
Start the engine.

6
Using the output state control option (RPM#) on WDS, raise the engine speed to between 3600 rpm and 3700 rpm.


7
Operate the special tool until the vane control lever reaches its stop.

8
Observe the reading of the WDS datalogger MAP signal.


Is the MAP reading a minimum of 1.95 bar?
Yes
NO fault is indicated with the turbocharger or its control systems. To continue diagnostics,
REFER to: Fuel Charging and Controls (303-04E Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Diagnosis and Testing).
No
CHECK the exhaust gas recirculation (EGR) valve for partial obstruction or sticking open. REPAIR or INSTALL new as required. TEST the system for normal operation.CHECK the air induction system for leaks or blockages. REPAIR or INSTALL new as required. TEST the system for normal operation.If no fault is found with the EGR valve or air intake system, INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
D3: CHECK THE VACUUM DIAPHRAGM UNIT

1
Stop the engine.


2
Disconnect the vacuum line from the vacuum diaphragm unit.


3
Install the special tool to the vacuum diaphragm unit.

4
Operate the special tool and observe the diaphragm actuator rod.


Does the diaphragm actuator rod travel its maximum distance and the vane control lever reach its stop?
Yes
CHECK the vacuum diaphragm unit vacuum control pipe for leaks or restriction. INSTALL a new pipe as required. If no fault is found, continue the diagnostic using WDS.
No
INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.

PINPOINT TEST E : POOR ENGINE PERFORMANCE
TEST CONDITIONS DETAILS/RESULTS/ACTIONS
E1: CHECK THE WASTEGATE ACTUATOR CONTROL PIPE FOR BLOCKAGE

1
Remove the wastegate actuator control pipe.

2
Install the special tool to one end of the wastegate actuator control pipe.

3
Operate the hand vacuum pump and observe the reading.


Is a reading present?
Yes
INSTALL a new wastegate actuator control pipe. TEST the system for normal operation.
No
GO to E2.
E2: CHECK THE WASTEGATE ACTUATOR DIAPHRAGM FOR LEAKS

1
Connect the free end of the wastegate control pipe to the wastegate actuator.

2
Operate the hand vacuum pump and observe the reading.


Does the pump hold vacuum?
Yes
GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls (303-04D Fuel Charging and Controls - 2.0L Duratorq-Di/TDDi (Puma) Diesel, Diagnosis and Testing).
No
INSTALL a new turbocharger.
REFER to: Turbocharger - Vehicles With: Turbocharger Variable Vane Vacuum Actuator (303-04F Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel, Removal and Installation).
TEST the system for normal operation.


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