Ford Falcon. Manual - part 174
303-04b-6
Fuel Charging and Controls — Turbocharger
303-04b-6
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
G99922 en