Hand Vacuum/Pressure Pump 416 - D001 (23 - 036A) : Special Tool(s)

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Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV)

Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW)
Diesel - Turbocharger1.6L Duratorq-TDCi (DV) Diesel
Focus 2004.75 (07/2004-)

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Diagnosis and Testing

Special Tool(s)
Hand Vacuum/Pressure Pump

416 - D001 (23 - 036A)
Inspection and Verification

NOTE:It is normal for a small amount of combustion gas to pass into the crankcase. This gas is scavenged into the air intake system through the
positive crankcase ventilation (PCV) system, which incorporates an oil separator. Some engine oil, in the form of a vapour is carried into the air
intake system with the blow-by gases (this engine oil also contributes to valve seat durability). This means that oil will collect inside the air intake
components and the turbocharger. 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 or seize. Do not install a new turbocharger due to oil inside the turbocharger or
the air intake components. If a leak is detected in the oil supply or return tubes or connections, locate and rectify the source. Do not install a new
turbocharger due to an oil leak.
1. 1. Verify the customer concern.
2. 2. Visually inspect for obvious signs of mechanical damage.
Visual Inspection Chart
Mechanical
Oil leak(s)
Air cleaner element
Air cleaner outlet pipe
Air cleaner intake pipe
Turbocharger oil supply or oil return tube
Vacuum diaphragm unit - vehicles with variable vane turbocharger
Wastegate control valve - vehicles with fixed vane turbocharger
Turbocharger
Charge air cooler
Electrical
Wiring harness
PCM
3. 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
NOTE:The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or serviced separately.
The wastegate control valve is a fixed part of the turbocharger and cannot be adjusted or serviced separately.
Symptom
Possible Sources
Action
Blue smoke with
* Turbocharger compressor rubbing on
* GO to Pinpoint Test A.
excessive turbocharger housing walls.
noise
* Turbocharger turbine rubbing on housing
walls.
* Turbocharger bearings and oil seal(s).
* Turbocharger oil supply tube blocked or
damaged.
Blue smoke without
* Turbocharger oil return tube blocked or * GO to Pinpoint Test B.
excessive turbocharger damaged.
noise
Poor engine
* Vacuum diaphragm unit vacuum line(s) - * CHECK all vacuum line(s) are installed and no signs of air leaks are present. REPAIR
performance
vehicles with variable vane turbocharger.
as necessary.
* Unauthorized adjustment of the vacuum * The vacuum diaphragm unit actuator rod is factory set and must not be adjusted.
diaphragm unit actuator rod - vehicles
CHECK the paint seal on the vacuum diaphragm unit actuator rod has not been
with variable vane turbocharger.
broken. If the paint seal has been broken, INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel
Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L
Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and
Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level
Code: K (303-04I Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi
(DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel,
Removal and Installation).
* Vacuum diaphragm unit actuator rod * CHECK the vacuum diaphragm unit actuator rod moves freely. If the vacuum
vehicles with variable vane turbocharger.
diaphragm unit actuator rod does not move freely. CHECK for signs of damage or
signs of foreign material. REPAIR as necessary.
* GO to Pinpoint Test C.
* Wastegate control valve line(s) - vehicles * CHECK all line(s) are installed and no signs of air leaks are present. REPAIR as
with fixed vane turbocharger.
necessary.
* Unauthorized adjustment of the
* The wastegate control valve actuator rod is factory set and must not be adjusted.
wastegate control valve actuator rod CHECK the paint seal on the wastegate control valve actuator rod has not been
vehicles with fixed vane turbocharger.
broken. If the paint seal has been broken, INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04, Removal
and Installation).
* Wastegate control valve actuator rod * CHECK the wastegate control valve actuator rod moves freely. If the wastegate
vehicles with fixed vane turbocharger.
control valve actuator rod does not move freely. CHECK for signs of damage or signs
of foreign material. REPAIR as necessary.
* GO to Pinpoint Test D.
Pinpoint Tests
PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE

TEST CONDITIONS
A1: INSPECT THE TURBOCHARGER ROTOR VANES FOR DAMAGE
1 Detach the turbocharger intake pipe.
DETAILS/RESULTS/ACTIONS
http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1110&proc-uid=G165374&guid... 13.08.2009
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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 - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04 Fuel Charging and Controls Turbocharger, Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls - Turbocharger 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel, Removal and
Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel
Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L
Duratorq-TDCi (DW) Diesel, Removal and Installation).
TEST the system for normal operation.
No
GO to A4.
A3: CHECK THE TURBOCHARGER BEARINGS FOR EXCESSIVE MOVEMENT
NOTE:A small amount of movement in the bearings is normal.
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 that the rotor spins freely within the housing.
Does the rotor spin freely within the housing with no excessive movement?
Yes
GO to A4.
No
INSTALL a new turbocharger.
Installation) /
A4: CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR BLOCKAGE
1 Remove the oil supply tube from the turbocharger and the cylinder block.
2 Using workshop compressed air, check the turbocharger oil supply tube for blockage or signs of damage.
Are there any signs of blockage or damage?
Yes
INSTALL a new turbocharger oil supply tube. TEST the system for normal operation.
No
Installation) /
PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE

TEST CONDITIONS
B1: CHECK THE TURBOCHARGER OIL RETURN PIPE
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Remove the turbocharger oil return pipe.
2 Using workshop compressed air, check the turbocharger oil return pipe for blockage or signs of damage.
Are there any signs of blockage or damage?
Yes
INSTALL a new turbocharger oil return pipe. TEST the system for normal operation.
No
GO to Fuel Charging and Controls for further diagnostics.
REFER to: Fuel Charging and Controls (303-04F Fuel Charging and Controls - 1.6L Duratorq-TDCi (DV) Diesel,
Diagnosis and Testing).
PINPOINT TEST C : POOR ENGINE PERFORMANCE - VEHICLES WITH VARIABLE VANE TURBOCHARGER
TEST CONDITIONS
C1: CHECK THE VACUUM DIAPHRAGM UNIT VACUUM LINE FOR BLOCKAGE
1 Disconnect the vacuum diaphragm unit vacuum line at both ends.
2
3
Block the vacuum line at the vacuum diaphragm unit end.

Install the special tool to the other end of the vacuum diaphragm unit vacuum line.
4 Operate the hand vacuum pump and observe the reading.

Does the vacuum pump hold a vacuum?
Yes
GO to C2.
No
INSTALL a new vacuum diaphragm unit vacuum line. TEST the system for normal operation.
C2: CHECK THE VACUUM DIAPHRAGM UNIT FOR LEAKS
1 Install the special tool to the vacuum diaphragm unit.

Yes
GO to C3.
No
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel,
Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging
and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L DuratorqTDCi (DW) Diesel, Removal and Installation).
C3: CHECK THE VACUUM DIAPHRAGM UNIT ACTUATOR ROD MOVEMENT
1 Operate the hand vacuum pump until a vacuum of 65 Kpa is achieved. Measure the distance travelled by the
vacuum diaphragm unit actuator rod.
Does the vacuum diaphragm unit actuator rod move between 9 mm and 11 mm?
Yes
No
CHECK for signs of damage or signs of foreign material in the turbocharger vanes. INSTALL a new turbocharger.
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS) (303-04I Fuel Charging and Controls Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel,
Removal and Installation) /
Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K (303-04I Fuel Charging
and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L DuratorqTDCi (DW) Diesel, Removal and Installation).
Page 4 of 4
PINPOINT TEST D : POOR ENGINE PERFORMANCE - VEHICLES WITH FIXED VANE TURBOCHARGER
TEST CONDITIONS
D1: CHECK THE WASTEGATE CONTROL VALVE LINE FOR BLOCKAGE
1 Disconnect the wastegate control valve line at both ends.
2
3
Block the wastegate control valve line at the wastgate control valve end.
Install the special tool to the other end of the wastegate control valve line.

Yes
GO to D2.
No
INSTALL a new wastegate control valve line. TEST the system for normal operation.
D2: CHECK THE WASTEGATE CONTROL VALVE FOR LEAKS
1 Install the special tool to the wastegate control valve.

Yes
GO to D3.
No
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04 Fuel Charging and Controls Turbocharger, Removal and Installation).
D3: CHECK THE WASTEGATE CONTROL VALVE ACTUATOR ROD MOVEMENT
1 Operate the hand vacuum pump until a vacuum of 65 Kpa is achieved. Measure the distance travelled by the
wastegate control valve actuator rod.
Does the wastegate control valve actuator rod move between 9 mm and 11 mm?
Yes
No
REFER to: Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS) (303-04 Fuel Charging and Controls Turbocharger, Removal and Installation).

Hand Vacuum/Pressure Pump 416 - D001 (23 - 036A) : Special Tool(s)

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Page 1 of 4

Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV)

Focus 2004.75 (07/2004-)

Diagnosis and Testing

Hand Vacuum/Pressure Pump

Inspection and Verification

PINPOINT TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE

Inspect the turbocharger rotor vanes for damage.

Is there visible damage to the rotor vanes?

PINPOINT TEST B : BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE

Remove the turbocharger oil return pipe.

Block the vacuum line at the vacuum diaphragm unit end.

4 Operate the hand vacuum pump and observe the reading.

2 Operate the hand vacuum pump and observe the reading.

TEST the system for normal operation.

4 Operate the hand vacuum pump and observe the reading.

2 Operate the hand vacuum pump and observe the reading.

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