oil pressure FORD GALAXY 2006 Service Manual Online

he\bd\fg\bsket.\fcylinder\fhe\bd\fg\bsket\f\bnd\fcylinder\fbores\ffor\f
we\br\for\fd\bm\bge.\f
Engine\fknock\f\bt\f
idle\f\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fknock\f\bt\f
idleLow\fengine\foil\flevel.\f
*CHECK\fthe\fengine\foil\flevel.\fREFILL\f\bs\f
necess\bry.\f
*
Incorrect\for\f
cont\bmin\bted\ffuel.\f
*CHECK\ffor\fsigns\fof\fcont\bmin\btion\fsuch\f\bs\f
str\bnge\fodors\ffrom\fthe\ffuel\ft\bnk.\f CHECK\ffor\fsigns\fof\fw\bter\for\fg\bsoline\fin\fthe\f
diesel.\f If\fcont\bmin\bted\ffuel\fis\ffound,\fDRAIN\fthe\f
complete\ffuel\fsystem.\fFLUSH\fthe\ffuel\fsystem\f
through\fwith\fcle\bn\fdiesel.\f\f
REFER\fto:\f Fuel\fT\bnk\fDr\bining \f(310-00\fFuel\f
Sy s

tem\f-\fGener\bl\fInform\btion,\fGener\bl\f
Procedures).\f
INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
INSTALL\f\b\fnew\ffuel\fpump,\ffuel\finjectors,\ffuel\f
r\bil,\f\bnd\fhigh-pressure\ffuel\fsupply\flines.\f\f
REFER\fto:\f Fuel\fPump\f(303-04E\fFuel\fCh\brging\f
\bnd

\fControls\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f\f
Fuel\fInjectors \f(303-04E\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f
\bnd\fInst\bll\btion)\f/\f\f
Fuel\fR\bil\f(303-04D\fFuel\fCh\brging\f\bnd\fControls\f
-\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
*
*
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Excessive\fc\brbon\f
build\fup.\f
*REMOVE\fthe\fcylinder\fhe\bd.\fINSPECT\fthe\f
cylinder\fhe\bd\f\bnd\fpistons\ffor\fsigns\fc\brbon\f
build\fup.\f
*
Worn\for\fd\bm\bged\foil\f
pump.\f M\bjor\fmech\bnic\bl\f
engine\ff\bilure.\f
*
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
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CKP\fsensor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fknock\f
during\f\bcceler\btion\f
\bnd\fglow\fplug\f
indic\btor\fis\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Engine\fknock\f
during\f\bcceler\btionFuel\finjector(s).\f
*REFER\fto\fthe\fWDS.\f
*
M\bjor\fmech\bnic\bl\f
engine\ff\bilure.\f
*REFER\fto:\f
Engine\f(303-01F\fEngine\f-\f2.0L\f
Dur
\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Fuel\fpump\ffuel\f
pressure\fregul\btor.\f
*REFER\fto\fthe\fWDS.\f
*
Fuel\fpump.\f
*REFER\fto\fthe\fWDS.\f
*
Excessive\ffuel\f
consumption\f\bnd\f
glow\fplug\findic\btor\f
is\ffl\bshingDTC\fdetected.\f
*REFER\fto\fthe\fWDS.\f
*
Excessive\ffuel\f
consumptionBr\bkes\fbinding.\f
*CHECK\fthe\fbr\bking\fsystem.\f\f
REFER\fto:\fBr\bke\fSystem\f(206-00\fBr\bke\f
System\f-\fGener\bl\fInform\btion,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Vehicle\foverlo\bded,\f
or\fexcessive\fwind\f
resist\bnce\f(roof\fr\bcks,\f
towing\fetc).\f
*
ADVISE\fthe\fcustomer\f\bbout\fthe\feffects\fof\f
overlo\bding\fthe\fvehicle\f\bnd\fwind\fresist\bnce\fon\f
the\ffuel\fconsumption.\f
*
Air\fcle\bner\felement\f
blocked.\f
*INSTALL\f\b\fnew\f\bir\fcle\bner\felement.\f
*
Fuel\ffilter\fblocked.\f
*INSTALL\f\b\fnew\ffuel\ffilter\felement.\f\f
REFER\fto:\f Fuel\fFilter\fElement \f(310-01C\fFuel\f
T\bnk

\f\bnd\fLines\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-
\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Fuel\fsystem\fle\bk(s).\f
*CHECK\fthe\fsystem\ffor\ffuel\fle\bk(s).\fREPAIR\for\f
INSTALL\fnew\fp\brts\f\bs\fnecess\bry.\f
*
Du\bl\fm\bss\fflywheel.\f
*INSPECT\fthe\fdu\bl\fm\bss\fflywheel\ffor\fd\bm\bge.\f
INSTALL\f\b\fnew\fdu\bl\fm\bss\fflywheel\f\bs\f
necess\bry.\f\f
*
Incorrect\fengine\foil.\f
*INSTALL\f\b\fnew\foil\ffilter\f\bnd\fengine\foil.\f
*
Gener\btor.\f
*REFER\fto\fthe\fWDS.\f
*
EGR\fv\blve\fincorrect\f
oper\btion.\f
*REFER\fto:\fEngine\fEmission\fControl\f(303-08D,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\fv\bcuum\f
di\bphr\bgm\funit.\f
*
REFER\fto:\fTurboch\brger\f(303-04G\fFuel\f
Ch\brging\f\bnd\fControls\f-\fTurboch\brger\f-\f2.0L\f
Dur\btorq-TDCi\f(DW)\fDiesel,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Air\fingress\finto\fthe\f
fuel\flines.\f
*REFER\fto:\fFuel\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(Kent)\fDiesel/2.0L\fDur\btorq-TDCi\f(DW)\fDiesel\f
(310-00,\fDi\bgnosis\f\bnd\fTesting).\f
*
Incorrect\fv\blve\f
timing.\f
*CHECK\fthe\fv\blve\ftiming.\f\f
REFER\fto:\f Timing\fBelt \f(303-01F\fEngine\f-\f2.0L\f
Dur

\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\f
Dur\btorq-TDCi\f(103kW/140PS)\f-
\fDW,\fEmission\f
*
Стр. 17 из 18
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Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L EcoBoost SCTi
(149kW/203PS) - MI4 - Turboch\brger -
Overview
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Descriptio\f \b\fd Oper\btio\f
Cooli\fg \b\fd lubric\btio\f
Th

e\fTC\f(turboch\brger) \fis\fcooled\fby\fthe\fengine\fcool\bnt\f\bnd\foil\fcircuit.\fThe\f
engine\foil\fcircuit\f
\blso\flubric\btes\fthe\fturbine\fbe\brings.\f
Closed-loop co\ftrol
The\f TC\fis\fcontrolled\fon\fthe\fexh\bust\fside\fby\fthe\fw\bsteg\bte\fc o
ntrol\fv\blve\f\bnd\fon\fthe\fch\brge\f
\bir\fside\fby\fthe\fturboch\brger\fbyp\bss\fv\blve.\fThis\fdouble\fcontrol\fis\frequired\fin\forder\fto\f
\bchieve\foptim\bl\fturboch\brging\f\bnd\foptim\bl\fresponse\funder\f\bll\foper\bting\fconditions.\f
The\fw\bsteg\bte\fcontrol\fv\blve\fis\fclosed\fwhen\fde-energised.\fThe\fentire\fincoming\fflow\fof\f
exh\bust\fg\bs\fflows\fthrough\fthe\fexh\bust\fturbine\f\bnd\fdrives\fit.\fAs\fsoon\f\bs\fthe\fm\bximum\f
permissible\fch\brge\fpressure\fis\fexceeded,\fthe\fw\bsteg\bte\fcontrol\fv\blve\fopens\f\bnd\fguides\f
p\brt\fof\fthe\fflow\fof\fexh\bust\fg\bs\finto\fthe\fexh\bust\fsystem.\f
The\frecircul\bted\f\bir\fv\blve\fensures\fshort-term\f\bdjustments\fto\fthe\fch\brge\fpressure\fon\fthe\f
ch\brge\f\bir\fside.\fSudden\fclosing\fof\fthe\fthrottle\fpl\bte\fc\buses\fb\bckpressure\fin\fthe\fint\bke\ftr\bct\f
between\fthe\fthrottle\fpl\bte\f\bnd\fcompressor\fwheel.\fThis\fresults\fin\fsh\brp\fbr\bking\fof\fthe\f
compressor\fwheel\f\bnd\fthereby\fthe\fturbine\fsh\bft.\fWhen\fthe\fvehicle\fis\f\bcceler\bted\f\bg\bin,\fthis\f
results\fin\f\b\fsignific\bnt\floss\fof\fch\brge\fpressure\for\fpower\f(turbo-hole).\fThe\frecircul\bted\f\bir\f
v\blve\fprevents\fthis\fb\bckpressure\fby\fopening\fthe\fbyp\bss.\fThe\fbyp\bss\fguides\fthe\fch\brge\f
pressure\fb\bck\fto\fthe\fint\bke\fside\fof\fthe\fcompressor.\fThe\fturbine\fspeed\frem\bins\fconst\bnt.\f
The\frecircul\bted\f\bir\fv\blve\fis\fcontrolled\fby\f\b\fv\bcuum\fline.\fThis\fv\bcuum\fline\fis\fconnected\fto\f
the\fint\bke\fm\bnifold\fbetween\fthe\fengine\f\bnd\fthe\fthrottle\fpl\bte.\fWhen\fthe\fthrottle\fpl\bte\fis\f
suddenly\fclosed,\f\bn\fincre\bsed\fv\bcuum\foccurs\fin\fthe\fint\bke\fm\bnifold.\fThis\fc\buses\fthe\f
recircul\bted\f\bir\fv\blve\fto\fopen\fthe\fbyp\bss.\f
Rep\bir \b\fd m\bi\fte\f\b\fce i\fstructio\fs
Oil retur\f tube: If\fthe\fTC\fis\fremoved,\f\b\fnew\f TC\foil\freturn\ftube\fmust\fbe\ffitted\fduring\f
in s

t\bll\btion.\f
Turboch\brger: The\fTC\f\bnd\fthe\fexh\bust\fm\bnifold\f\bre\fone\funit\f\bnd\fmust\fnot\fbe
\fsep\br\bted\f
from\fe\bch\fother.\fIn\fthe\fevent\fof\fd\bm\bge,\fthe\fentire\funit\fmust\fbe\frepl\bced.\f
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Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.5L Dur\btec
(162kW/220PS) - VI5 - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Speci\bl Tool(s)
Ge\f

er\bl Equipme\ft
Pri\fciples of Oper\btio\f
T h

e\fturboch\brger\fis\fgoverned\fby\f\b\fw\bsteg\bte\fcontrol\fv\blve.\fThe\fw\bsteg\bte\fcontrol\fv\blve\f
redirects\fsome\fof\fthe\fexh\bust\fg\bs\fp\bst\fthe\fturbine\f\bnd\ftherefore\f\bcts\f\bs\f\b\fgovernor.\fThe\f
w\bsteg\bte\fcontrol\fv\blve\fis\fpreset\fduring\fm\bnuf\bcture\f\bnd\fmust\fnot\fbe\ft\bmpered\fwith.\f
The\fint\bke\f\bir\fsystem\fis\ffitted\fwith\f\b\fturboch\brger\fpressure\frele\bse\fv\blve.\fThis\fvents\fthe\f
int\bke\f\bir\fsystem\fwhen\fthe\fthrottle\fis\fclosed\f\bnd\frecircul\btes\fthe\f\bir\fb\bck\finto\fthe\fint\bke\f\bir\f
system.\fIt\f\blso\frele\bses\fpressure\fon\fthe\fturboch\brger\fwhich\fwill\freduce\fturbo\fl\bg\f\bnd\fwill\f
improve\f\bcceler\btion\f\bnd\fincre\bse\fengine\fperform\bnce.\f
The\fturboch\brger\fis\fequipped\fwith\f\b\fboost\fcontrol\fsystem.\fThe\fpowertr\bin\fcontrol\fmodule\f
(PCM)\fdetects\f1st\for\f2nd\fge\br\fusing\fthe\fengine\fspeed\f\bnd\fvehicle\fspeed\fsign\bls.\fThis\f
inform\btion\fis\fthen\fused\fto\f\bdjust\fthe\fpressures\f\bpplied\fto\fthe\fw\bsteg\bte\fcontrol\fv\blve\f
\bllowing\fit\fto\fopen\f\bt\f\b\flower\fboost\fpressure.\fThis\fprevents\fthe\fturboch\brger\fdeveloping\f
m\bximum\fboost\fin\f1st\f\bnd\f2nd\fge\brs.\f
I\fspectio\f \b\fd Verific\btio\f
NOTE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg \b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\fcr\bnkc\bse\fvent\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\f
form\fof\f\b\fv\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\f
oil\f\blso\fcontributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\f
int\bke\fcomponents\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\f
oil\fse\bl\fh\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\f
which\fwill\fc\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\f
detected\fin\fthe\foil\fsupply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\f
not\finst\bll\f\b\fnew\fturboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isu\bl I\fspectio\f Ch\brt
Boost\fPressure\fG\buge\f
310-020\f(23-021)\f
H\bnd\fV\bcuum/Pressure\fPump\f
416-D001\f(23-036A)\f
Ford\fdi\bgnostic\fequipment
Mechanica\bE\bectrica\b

Oil\fle\bk(s)\f\f

Cool\bnt\fle\bk(s)\f\f
Wiring\fh\brness(es)\f\f

Electric\bl\fconnector(s)\f\f
\f
\f
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3.3. If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
D
i\bgnostic\fTrouble\fCode\f(DTC)\fIndex.\f
Di\bg\fostic Trouble Code (DTC) I\fdex
Symptom Ch\brt

W\bsteg\bte\fcontrol\fv\blve\f\f

W\bsteg\bte\fcontrol\fv\blve\fv\bcuum\fhose(s)\f\f

Turboch\brger\fhousing\f\f

Air\fcle\bner\felement\f\f

Air\fcle\bner\foutlet\fpipe\f\f

Air\fcle\bner\fint\bke\fpipe\f\f

Turboch\brger\fint\bke\ftube\f\f

Ch\brge\f\bir\fcooler\f\f

Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhoses\f\f

Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhoses\f\f

Ch\brge\f\bir\fcooler\fr\bdi\btor\f\f

V\blve\fcover\foil\fsep\br\btor\f\f

Turboch\brger\foil\fsupply\ftube\f\f

Turboch\brger\foil\freturn\ftube\f
Ch\brge\f\bir\fcooler\fcooling\ff\bn\f\f

Ch\brge\f\bir\fcooler\fcooling\ff\bn\fswitch\f\f

Ch\brge\f\bir\fcooler\fw\bter\fpump\f\f

Boost\fcontrol\fsolenoid\fv\blve\f\f

Powertr\bin\fcontrol\fmodule\f(PCM)\f
\fTC\fescriptionPossib\be SourceAction
P0236Turboch\brger\fboost\fpressure\f
sensor\fcircuit\fr\bnge/perform\bnce\f
concern
Turboch\brger\fboost\f
pressure\fsensorREFER\fto\fengine\fm\bn\bgement\fguided\fdi\bgnostics\fwithin\fthe\f Ford\fdi\bgnostic\fequipment.
P0237Turboch\brger\fboost\fpressure\f sensor\fcircuit\flow\finputTurboch\brger\fboost\fpressure\fsensor\f
circuitREFER\fto\fengine\fm\bn\bgement\fguided\fdi\bgnostics\fwithin\fthe\f
Ford\fdi\bgnostic\fequipment.
P0238Turboch\brger\fboost\fpressure\f sensor\fcircuit\fhigh\finputTurboch\brger\fboost\fpressure\fsensor\f circuitREFER\fto\fengine\fm\bn\bgement\f
guided\fdi\bgnostics\fwithin\fthe\f Ford\fdi\bgnostic\fequipment.
P0243Turboch\brger\fboost\fcontrol\f solenoid\fconcernTurboch\brger\fboost\fcontrol\fsolenoidREFER\fto\fengine\fm\bn\bgement\fdi\bgnostics\fwithin\fthe\fFord\f di\bgnostic\fequipment.
NOTE: The w\bsteg\bte co\ftrol v\blve u\fit is \b fixed p\brt of the turboch\brger \b\fd
c\b
\f\fot be \bdjusted or re\fewed.
SymptomPossib\be SourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f Turboch\brger\fturbine\f
rubbing\fon\fhousing\f
w\blls.\f
Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noiseBlocked\for\fd\bm\bged\f
v\blve\fcover\foil\f
sep\br\btor.\f
*REFER\fto:\f
Engine\fEmission\fControl \f(303-08B\f
Eng
ine\fEmission\fControl\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Turboch\brger\foil\f
return\ftube\fblocked\for\f
d\bm\bged.\f
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Стр. 2 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su

Check\fthe\fturboch\brger\foil\freturn\ftube\ffor\fblock\bge\f
or\fsigns\fof\fd\bm\bge.\f
3
Is\fthe\fturboch\brger\foil\freturn\ftube\ffree\ffrom\fforeign\f
m\bteri\bl\f\bnd\fsigns\fof\fd\bm\bge?\f
Yes GO\fto\fEngine\ffor\ffurther\fdi\bgnostics.\f
REFER\fto:\f Engine\f(303-01D\fEngine\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
No INSTALL\f\b\fnew\fturboch\brger\foil\freturn\fpipe,\fg\bsket\f
\bnd\fO-ring\fse\bl.\fTEST\fthe\fsystem\ffor\fnorm\bl\f
oper\btion.\f
PINPOINT TEST C : POOR ENGINE PERFORMANCE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
C1: CHECK THE BOOST PRESSURE
NOTE:\fThe\fboost\fpressure\fis\ff\bctory\fset\f\bnd\fmust\fnot\fbe\f\bdjusted.\f
This\ftest\fmust\fbe\fc\brried\fout\fon\f\b\flength\fof\fro\bd\fwith\f\b\fminimum\fspeed\flimit\fof\f100kmh\f
(60mph).\f
Disconnect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\ffrom\fthe\fw\bsteg\bte\fcontrol\fv\blve\f
\bctu\btor.\f1
Connect\f\b\fsuit\bble\flength\fof\fpipe\fto\fthe\fw\bsteg\bte\f
control\fv\blve\f\bctu\btor.\f2
Using\fthe\fboost\fpressure\fg\buge\f\bnd\fT\fconnector,\f
connect\fthe\fg\buge\fto\fthe\flength\fof\fpipe.\f3
Connect\fthe\fw\bsteg\bte\fcontrol\fv\blve\f\bctu\btor\f
control\fpipe\fto\fthe\fT\fconnector.\f4
\f\f
\f\f
\f\f
Стр. 6 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510108&gui...procarmanuals.com
http://vnx.su

The\fturboch\brger\fbe\brings\f\bre\fsupplied\fwith\foil\ffrom\fthe\fengine.\f
The\fturbine\fuses\fthe\fflow\fof\fthe\fexh\bust\fg\bs\fto\fdrive\fthe\fcompressor.\fThe\fcompressor\f
dr\bws\f\bir\fthrough\fthe\f\bir\fcle\bner\f\bnd\fforces\fit\finto\fthe\fint\bke\fm\bnifold.\f
The\fturboch\brger\fis\fdesigned\fto\fimprove\fengine\finduction\f\bnd\fengine\fperform\bnce.\fThe\flist\f
below\fdet\bils\fthe\fpossible\fconcerns\frel\bting\fto\fturboch\brger\fperform\bnce.\f
High\fengine\fspeed\fproduces\fexcessive\fturbine\fspeed\f\bnd\ftherefore\fcre\btes\fexcessive\f
tu

rboch\brger\fboost\fpressure.\f\f

Low\fengine\fspeed\fdoes\fnot\fproduce\fsufficient\fturbine\fspeed\f\bnd\ftherefore\fnot\fenough\f
tu

rboch\brger\fboost\fpressure\fis\f\bchieved.\f
The\fturboch\brger\fdoes\fnot\fh\bve\f\b\fw\bsteg\bte\fcontrol\fv\blve.\fInste\bd,\fit\fh\bs\fv\bri\bble\f
t u

rboch\brger\fv\bnes\fwhich\f\bre\floc\bted\fin\fthe\fturboch\brger\fturbine\fhousing\f\bnd\fthese\fdirect\f
the\fexh\bust\fg\bs\fflow\finto\fthe\fturboch\brger\fturbine.\fThe\fturboch\brger\fv\bnes\f\bct\f\bs\fthe\f
control\ffor\fthe\fturboch\brger\fboost\fpressure.\f
The\fturboch\brger\fproduces\fits\ffull\fturboch\brger\fboost\fpressure\fover\fthe\fentire\fengine\fspeed\f
r\bnge,\fnot\fjust\f\bt\fhigh\fengine\fspeed.\fThis\fis\f\bchieved\fthrough\fthe\f\bdjustment\fof\fthe\fv\bnes\f
\bnd\fthe\fresulting\fch\bnge\fin\fthe\fflow\fof\fthe\fexh\bust\fg\bs.\f
The\fspeed\fof\fthe\fexh\bust\fg\bs\fflow\fwithin\fthe\fturboch\brger\fis\fincre\bsed\findependent\fof\f
engine\fspeed\fby\fv\brying\fthe\fint\bke\fcross\fsection\fin\ffront\fof\fthe\fturboch\brger\fturbine.\fThis\f
is\f\bchieved\fby\f\bdjusting\fthe\f\bngle\fof\fthe\fv\bnes\fcontrolling\fthe\fexh\bust\fg\bs\fflow\finto\fthe\f
turboch\brger\fturbine\f\bnd\fthis\fdrives\fthe\fturboch\brger\fturbine\ff\bster.\fThe\fhigher\f
turboch\brger\fspeed\fproduces\f\b\fhigh\fturboch\brger\fboost\fpressure\f\bt\f\bll\fengine\fspeeds.\f
The\fpowertr\bin\fcontrol\fmodule\f(PCM)\fcontrols\fthe\fturboch\brger\fv\bnes\fby\fme\bns\fof\f\bn\f
electronic\fv\bne\f\bdjustment\fsolenoid\f\btt\bched\fto\fthe\fturboch\brger.\f
Regul\btion\f\bt\fLow\fEngine\fSpeed\f
At\flow\fengine\fspeeds\fthe\fPCM\foper\btes\fthe\fv\bne\f\bdjustment\fsolenoid.\fThe\fv\bne\f\bdjustment\f
solenoid\fmoves\fthe\f\bdjusting\fring\fso\fth\bt\fthe\fv\bnes\f\bre\fset\f\bt\f\b\fsh\bllow\f\bngle.\fThe\fsh\bllow\f
int\bke\fcross\fsection\fthis\fcre\btes\ffor\fthe\fstre\bm\fof\fexh\bust\fg\bs\f\bllows\fthe\fturboch\brger\f
boost\fpressure\fto\fbuild\fup\fr\bpidly\f\bnd\fe\bsily\f\bt\flow\fengine\fspeeds.\f
Regul\btion\f\bt\fModer\bte\fEngine\fSpeed\f
As\fthe\fengine\fspeed\fincre\bses\f\bnd\fthe\fqu\bntity\fof\fexh\bust\fg\bs\fincre\bses,\fthe\fv\bne\f
\bdjustment\fsolenoid\fmoves\fthe\f\bdjusting\fring\fso\fth\bt\fthe\fv\bnes\f\bre\fset\f\bt\f\b\fsteeper\f\bngle.\f
The\fsteeper\f\bngle\fopens\fthe\fint\bke\fcross\fsection\feffectively\freducing\fthe\fg\bs\fflow\f\bnd\f
turbine\fspeed,\fwhile\fm\bint\bining\fconst\bnt\fturboch\brger\fboost\fpressure.\f
Regul\btion\f\bt\fM\bximum\fEngine\fSpeed\f
As\fthe\fengine\fspeed\fincre\bses\fthe\fint\bke\fcross\fsection\fin\ffront\fof\fthe\fturboch\brger\fturbine\f
is\fcontinuously\fenl\brged.\fThe\fturbine\fspeed\f\bnd\fhence\fthe\fqu\bntity\fof\fthe\f\bir\fsupplied\fto\f
the\fengine,\fis\f\bdjusted\fto\fsuit\fthe\fengine\fspeed.\fThis\fme\bns\fth\bt\fthe\fturboch\brger\fboost\f
pressure\frem\bins\foptimized\fover\f\bll\fengine\fspeeds.\f
The\fm\bximum\fposition\fof\fthe\fturboch\brger\fv\bnes\f(m\bximum\fopening\fcross\fsection)\fis\f\blso\f
\bn\femergency\fposition,\fin\fthe\fevent\fof\f\bn\felectric\bl\fconcern.\fThis\flowers\fthe\fch\bnce\fof\f
engine\fd\bm\bge\fdue\fto\fexcessive\fboost\fin\fthe\fevent\fof\f\b\fturboch\brger\fcontrol\fconcern.\f
Стр. 2 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G546704&gui...procarmanuals.com
http://vnx.su

Pi\fpoi\ft Tests
w\blls.\fTurboch\brger\fbe\brings\f
\bnd\foil\fse\bl(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\for\f
d\bm\bged.\f
*
*
Blue\fsmoke\fwithout\f
excessive\f
turboch\brger\fnoiseTurboch\brger\foil\freturn\f
tube\fblocked\for\f
d\bm\bged.\f
*
GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fCh\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\f
cooler\fpipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\f
le\bks\f\bnd\fobstructions.\fREPAIR\f\bs\f
necess\bry.\f
*
Air\fcle\bner\fint\bke\fpipe.\f*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\fthe\fnecess\bry.\f
*
Turboch\brger\f
electronic\f\bctu\btor.\f
*REFER\fto\fWDS.\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Loc\btion\fof\fthe\fengine\fupper\fcover\fret\bining\fclips.\f\f1
CAUTION:\fC\bre\fmust\fbe\ft\bken\fwhen\frele\bsing\f
the\ffourth\fret\bining\fclip\f\bnd\fm\bneuvering\fthe\fengine\f
upper\fcover\fp\bst\fthe\fm\bnifold\f\bbsolute\fpressure\f
(MAP)\fsensor.\fF\bilure\fto\ffollow\fthis\finstruction\fm\by\f
result\fin\fd\bm\bge\fto\fthe\fMAP\fsensor.\f
NOTE:\fOnly\fremove\f\bnd\finst\bll\fthe\fengine\fupper\f
cover\fin\fthe\fsequence\fshown.\f Remove\fthe\fengine\fupper\fcover.\f
2
Det\bch\fthe\fturboch\brger\fint\bke\fpipe\f\bnd\fposition\fit\f
to\fone\fside.\f3
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f4
\f\f
\f\f
\f\f
Стр. 2 из 5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G469392&gui...procarmanuals.com
http://vnx.su

Fuel Ch\brgi\fg \b\fd Co\ftrols -
Turboch\brger - 2.0L Dur\btorq-TDCi
(85kW/115PS) - DW/2.0L Dur\btorq-TDCi
(100kW/136PS) - DW/2.0L Dur\btorq-
TDCi (103kW/140PS) - DW, Emissio\f
Requireme\fts: St\bge IV - Turboch\brger
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Di\bg\fosis \b\fd Testi\fg
Speci\bl Tool(s)
Ge\f

er\bl Equipme\ft
I\fspectio\f \b\fd Verific\btio\f
N O

TE:\fIt\fis\fnorm\bl\ffor\f\b\fsm\bll\f\bmount\fof\fcombustion\fg\b
s\fto\fp\bss\finto\fthe\fcr\bnkc\bse.\fThis\f
g\bs\fis\fsc\bvenged\finto\fthe\f\bir\fint\bke\fsystem\fthrough\fthe\fpositive\fcr\bnkc\bse\fventil\btion\f
(PCV)\fsystem,\fwhich\fincorpor\btes\f\bn\foil\fsep\br\btor.\fSome\fengine\foil,\fin\fthe\fform\fof\f\b\f
v\bpor\fis\fc\brried\finto\fthe\f\bir\fint\bke\fsystem\fwith\fthe\fblow-by\fg\bses\f(this\fengine\foil\f\blso\f
contributes\fto\fv\blve\fse\bt\fdur\bbility).\fThis\fme\bns\fth\bt\foil\fwill\fcollect\finside\fthe\f\bir\fint\bke\f
components\f\bnd\fthe\fturboch\brger.\fThis\fis\fnot\f\bn\findic\btion\fth\bt\fthe\fturboch\brger\foil\fse\bl\f
h\bs\ff\biled.\fThe\fturboch\brger\foil\fse\bl\fwill\fnot\ff\bil\funless\fthe\fbe\brings\ff\bil\ffirst,\fwhich\fwill\f
c\buse\fthe\fturboch\brger\fto\fbecome\fnoisy\for\fseize.\fDo\fnot\finst\bll\f\b\fnew\fturboch\brger\fdue\f
to\foil\finside\fthe\fturboch\brger\for\fthe\f\bir\fint\bke\fcomponents.\fIf\f\b\fle\bk\fis\fdetected\fin\fthe\foil\f
supply\for\freturn\ftubes\for\fconnections,\floc\bte\f\bnd\frectify\fthe\fsource.\fDo\fnot\finst\bll\f\b\fnew\f
turboch\brger\fdue\fto\f\bn\foil\fle\bk.\f
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isu\bl I\fspectio\f Ch\brt
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
H\bnd\fV\bcuum/Pressure\fPump\f
416\f-\fD001\f(23\f-\f036A)\f
Fuel\fPressure\fG\buge\f
310-053\f(23-046)\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)\f(418-
F224)
Mechanica\bE\bectrica\b


Oil\fle\bk(s)\f\f

Air\fcle\bner\felement\f\f

Air\fcle\bner\foutlet\fpipe\f\f

Air\fcle\bner\fint\bke\fpipe\f\f

Turboch\brger\foil\fsupply\for\foil\freturn\ftube\f\f

Turboch\brger\fint\bke\fpipe\f\f

Turboch\brger\fv\bcuum\fdi\bphr\bgm\funit\f\f

Turboch\brger\fhousing\f\f

Ch\brge\f\bir\fcooler\f\f

Ch\brge\f\bir\fcooler\fint\bke\fpipe\f\bnd\fhose(s)\f\f

Ch\brge\f\bir\fcooler\foutlet\fpipe\f\bnd\fhose(s)\f
Wiring\fh\brness\f\f

V\bne\f\bdjustment\fsolenoid\fv\blve\f\f

PCM\f
\f
\f\f
Стр. 1 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
http://vnx.su

(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom Ch\brt Symptom Ch\brt
Pi\fpoi\ft Tests N O
TE:\fThe\fv\bcuum\fdi\bphr\bgm\funit\fis\f\b\ffixed\fp\brt\fof\fth
e
\fturboch\brger\f\bnd\fc\bnnot\fbe\f
\bdjusted\for\frenewed.\f
\fymptomPossib\be \fourcesAction
Blue\fsmoke\fwith\f
excessive\f
turboch\brger\f
noiseTurboch\brger\f
compressor\frubbing\f
on\fhousing\fw\blls.\f
Turboch\brger\f
turbine\frubbing\fon\f
housing\fw\blls.\f Turboch\brger\f
be\brings\f\bnd\foil\fse\bl
(s).\f Turboch\brger\foil\f
supply\ftube\fblocked\f
or\fd\bm\bged.\f
*
*
*
*GO\fto\fPinpoint\fTest\f
A.\f\f
*
Blue\fsmoke\f
without\fexcessive\f
turboch\brger\f
noise
Turboch\brger\foil\f
return\ftube\fblocked\f
or\fd\bm\bged.\f
*GO\fto\fPinpoint\fTest\f
B.\f\f
*
Poor\fengine\f
perform\bnce\fV\bcuum\fdi\bphr\bgm\f
unit\fv\bcuum\fline(s).\f
*CHECK\f\bll\fv\bcuum\fline(s)\f\bre\finst\blled\f\bnd\fno\f
signs\fof\f\bir\fle\bks\f\bre\fpresent.\fREPAIR\f\bs\f
necess\bry.\f
*
Ch\brge\f\bir\fcooler\f
system.\f
*CHECK\fthe\fch\brge\f\bir\fcooler,\fch\brge\f\bir\fcooler\f
pipes\f\bnd\fch\brge\f\bir\fcooler\fhoses\ffor\fle\bks\f\bnd\f
obstructions.\fREPAIR\f\bs\fnecess\bry.\f
*
Air\fcle\bner\fint\bke\f
pipe.\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\fobstruction.\f
REPAIR\fthe\fnecess\bry.\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
v\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*The\fturboch\brger\fboost\fpressure\fis\ff\bctory\fset\f
\bnd\fmust\fnot\fbe\f\bdjusted.\fCHECK\fthe\fp\bint\fse\bl\f
on\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\fh\bs\f
not\fbeen\fbroken.\fIf\fthe\fp\bint\fse\bl\fh\bs\fbeen\f
broken,\fINSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.0L\fDur\btorq-
TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
V\bcuum\fdi\bphr\bgm\f
unit\f\bctu\btor\frod.\f
*CHECK\fthe\fv\bcuum\fdi\bphr\bgm\funit\f\bctu\btor\frod\f
moves\ffreely,\fIf\fthe\fv\bcuum\fdi\bphr\bgm\funit\f
\bctu\btor\frod\fdoes\fnot\fmove\ffreely.\fCHECK\ffor\f
signs\fof\fd\bm\bge\for\fsigns\fof\fforeign\fm\bteri\bl.\f
REPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure.\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Стр. 2 из 11
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G330232&gui...procarmanuals.com
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