turbocharger FORD GALAXY 2006 Service Repair Manual

Pi\fpoi\ft Tests
Poor\fengine\f
perform\bnce\fW\bsteg\bte\fcontrol\f
v\blve\f\bctu\btor\frod.\f V\bcuum\fline(s).\f
*
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Ch\brge\f\bir\fcooler\f
pipes\f Ch\brge\f\bir\fcooler\f
r\bdi\btor\f Ch\brge\f\bir\fcooler\f
w\bter\fpump\f Ch\brge\f\bir\fcooler\f
*
*
*
*REFER\fto\f
in\fthis\fsection. \f
*
Air\fcle\bner\fint\bke\f
pipe\f
*CHECK\fthe\f\bir\fcle\bner\fint\bke\fpipe\ffor\f
obstruction.\fREPAIR\f\bs\fnecess\bry.\f
*
Turboch\brger\fboost\f
pressure\f
*GO\fto\fPinpoint\fTest\f
C.\f\f
*
Un\buthorized\f
\bdjustment\fof\fthe\f
w\bsteg\bte\fcontrol\f
v\blve\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\fw\bsteg\bte\fcontrol\fv\blve\funit\f\bctu\btor\frod\f
h\bs\fnot\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-
04H\fFuel\fCh\brging\f
\bnd\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Ignition\fsystem.\f
*CHECK\fthe\fignition\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
Fuel\fch\brging\fsystem.\f*CHECK\fthe\ffuel\fch\brging\fsystem.\f\f
REFER\fto:\f Fuel\fCh\brging\f\bnd\fControls \f(303-04C\f
Fue

l\fCh\brging\f\bnd\fControls\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fDi\bgnosis\f\bnd\fTesting).\f
*
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
Remove\fthe\f\bir\fcle\bner.\f\f
REFER\fto:\f
Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Inspect\fthe\fturboch\brger\frotor\fv\bnes\ffor\fd\bm\bge.\f2
Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No
GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f1
\f\f
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of\fforeign\fm\bteri\bl.\f
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\f
\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
GO\fto\fA3.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\f
within\fthe\fhousing.\f

1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\f
th

e\fsh\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\f
bottom\fof\fthe\fbe\brings).\f

2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwithout\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No
I

NSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE:\fDisc\brd\fthe\fcopper\fw\bshers.\f
Disconnect\fthe\foil\fsupply\ftube\ffrom\fthe\f
tu
rboch\brger\f(exh\bust\fm\bnifold\fhe\btshield\f\bnd\f
ch\brge\f\bir\fcooler\fint\bke\fpipe\fshown\fremoved\ffor\f
cl\brity).\f1
NOTE:\fDisc\brd\fthe\fcopper\fw\bshers.\f
Disconnect\fthe\foil\fsupply\ftube\ffrom\fthe\fengine\f\bnd\f
re
move\fthe\foil\fsupply\ftube.\f2
Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f
\bir\fnozzle\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f3
Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f
Yes
\f\f
\f\f
\f\f
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GO\fto\fA5.\f\f
No I
NSTALL\f\b\fnew\foil\fsupply\ftube.\fINSTALL\f\b\fnew\f
turboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY
Using\fsome\fsuit\bble\fwelding\frod\fcheck\fthe\foil\f
supply\ftube\foil\fg\bllery\ffor\fblock\bge.\f1
Is\fthe\foil\fsupply\ftube\foil\fg\bllery\ffree\ffrom\fblock\bge?\f
Yes
INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No REMOVE\fthe\fblock\bge.\fINSTALL\f\b\fnew\f
turboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04H\fFuel\fCh\brging\f
\bnd

\fControls\f-\fTurboch\brger\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TEST CON\fITIONS\fETAILS/RESULTS/ACTIONS
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
NOTE:\fDisc\brd\fthe\fg\bsket.\f
Disconnect\fthe\fturboch\brger\foil\freturn\ftube\ffrom\f
th
e\fturboch\brger\f(turboch\brger\fhe\btshield\f\bnd\f
c\bt\blytic\fconverter\fshown\fremoved\ffor\fcl\brity).\f1
NOTE:\fDisc\brd\fthe\fO-ring\fse\bl.\f
Remove\fthe\fturboch\brger\foil\freturn\ftube\f
(t
urboch\brger\fhe\btshield\f\bnd\fc\bt\blytic\fconverter\f
shown\fremoved\ffor\fcl\brity).\f2
\f\f
\f\f
\f\f
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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
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Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\fof\f
foreign\fm\bteri\bl.\f1
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\fINSTALL\f\b\f
new\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
GO\fto\fA4.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\fwithin\f
the\fhousing.\f

1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\fthe\f
sh

\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\fbottom\fof\f
the\fbe\brings).\f

2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwith\fno\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No I

NSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
Remove\fthe\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
1
Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f2
\f\f
\f\f
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\bir\fnozzle,\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f
Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f
Yes GO\fto\fA5.\f\f
No I

NSTALL\f\b\fnew\fturboch\brger\f\bnd\fturboch\brger\foil\f
supply\ftube.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
Visu\blly\finspect\fthe\foil\fsupply\ftube\foil\fg\bllery\ffor\f
block\bge.\f1
Is\fthe\foil\fsupply\ftube\foil\fg\bllery\ffree\ffrom\fblock\bge?\f
Yes INSTALL\f\b\fnew\fturboch\brger\f\bnd\foil\fsupply\fpipe.\f\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con

trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No REMOVE\fthe\fblock\bge.\fINSTALL\f\b\fnew\fturboch\brger.\f
\f
REFER\fto:\f Turboch\brger \f(303-04I\fFuel\fCh\brging\f\bnd\f
Con
trols\f-\fTurboch\brger\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).\f
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f2
NOTE:\fDisc\brd\fthe\fg\bsket(s).\f
Remove\fthe\fturboch\brger\foil\freturn\fpipe.\f
3
\f\f
\f\f
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(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
http://vnx.su

Is\fthere\fvisible\fd\bm\bge\fto\fthe\frotor\fv\bnes?\f
Yes GO\fto\fA2.\f\f
No GO

\fto\fA3.\f\f
A2: CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR SYSTEM COMPONENTS
Check\fthe\fint\bke\f\bir\fsystem\fcomponents\ffor\fsigns\f
of\fforeign\fm\bteri\bl.\f1
Are\fthere\f\bny\fsigns\fof\fforeign\fm\bteri\bl?\f
Yes CLEAN\fthe\fint\bke\f\bir\fsystem\fcomponents.\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No GO\fto\fA4.\f\f
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:\fA\fsm\bll\f\bmount\fof\fmovement\fin\fthe\fbe\brings\fis\fnorm\bl.\f
M\bke\fsure\fthe\fturboch\brger\frotor\fspins\ffreely\f
within\fthe\fhousing.\f

1.\fWith\fthe\fturboch\brger\fst\btion\bry,\fgently\flift\f
th

e\fsh\bft\f(the\fsh\bft\fwill\fn\btur\blly\fl\by\fin\fthe\f
bottom\fof\fthe\fbe\brings).\f

2.\fM\bke\fsure\fthe\frotor\fspins\ffreely\fwithin\fthe\f
ho

using.\f
1
Does\fthe\frotor\fspin\ffreely\fwithin\fthe\fhousing\fwith\fno\f
excessive\fmovement?\f
Yes GO\fto\fA4.\f\f
No I

NSTALL\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
NOTE:\fDisc\brd\fthe\fcopper\fw\bshers.\f
Remove\fthe\fturboch\brger\foil\fsupply\ftube.\f
1
\f\f
\f\f
Стр. 4 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

Using\fworkshop\fcompressed\f\bir\f\bnd\f\b\fcompressed\f
\bir\fnozzle,\fcheck\fthe\foil\fsupply\ftube\ffor\fblock\bge.\f2
Is\fthe\foil\fsupply\ftube\ffree\ffrom\fblock\bge?\f
Yes GO\fto\fA5.\f\f
No
I

NSTALL\f\b\fnew\fturboch\brger\f\bnd\fturboch\brger\foil\f
supply\ftube.\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A5: CHECK THE TURBOCHARGER OIL SUPPLY TUBE OIL GALLERY FOR BLOCKAGE
Using\f\b\fsuit\bble\fwelding\ffiller\frod,\fcheck\fthe\foil\f
supply\ftube\foil\fg\bllery\ffor\fblock\bge.\f1
Is\fthe\foil\fsupply\ftube\foil\fg\bllery\ffree\ffrom\fblock\bge?\f
Yes GO\fto\fA6.\f\f
No R

EMOVE\fthe\fblock\bge.\fINSTALL\f\b\fnew\f
turboch\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
A6: CHECK THE TURBOCHARGER OIL SUPPLY TUBE NON RETURN VALVE FOR
CORRECT OPERATION AND BLOCKAGE
Remove\fthe\fturboch\brger\foil\fsupply\fpipe\funion\fnon\f
return\fv\blve.\f
1
\f\f
\f\f
Стр. 5 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

Inspect\fthe\fturboch\brger\foil\fsupply\fpipe\funion\ffor\f
block\bge.\f2
Is\fthe\foil\fsupply\fpipe\funion\fnon\freturn\fv\blve\ffree\fto\f
move\f\bnd\fthe\funion\ffree\ffrom\fblock\bge?\f\f
Yes INSTALL\f\b\fnew\fturboch\brger.\f\f
REFER\fto:\f Turboch\brger \f(303-04J\fFuel\fCh\brging\f
\bn d

\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No INSTALL\f\b\fnew\fturboch\brger\f\bnd\foil\fsupply\fpipe\f
non\freturn\fv\blve.\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
TEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER
NOISE
TE\fT CONDITION\fDETAIL\f/RE\fULT\f/ACTION\f
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
R\bise\f\bnd\fsupport\fthe\fvehicle.\fFor\f\bddition\bl\f
inform\btion,\f\f
REFER\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
1
Remove\fthe\fengine\fundershield.\f

Rot\bte\fthe\flocking\ft\bngs\fcounterclockwise.\f2
NOTE:\fDisc\brd\fthe\fg\bsket.\f
Remove\fthe\fturboch\brger\foil\freturn\fpipe.\f
3
\f\f
\f\f
Стр. 6 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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