Ford Galaxy / Ford S-MAX. Manual - part 398

NOTE: Only tighten the nuts and bolts finger tight at
this stage.

NOTE:
Make sure
that a new
component
is installed.
NOTE:
Make sure
that the
clamp is
installed to
the same
orientation
as when
removed.

1. Torque:

5 Nm

1. Torque: 25 Nm
2. Torque: 35 Nm
3. Torque: 23 Nm
4. Torque: 10 Nm
5. Torque: 10 Nm

CAUTION: Make sure that the inside of the pipe

ends are clean and free of oil residue.

6. Install the following items:

Refer to:

Catalytic Converter

(309-00D Exhaust

System - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Removal and Installation).
Refer to:

Air Cleaner

(303-12D Intake Air

Distribution and Filtering - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-TDCi
(92kW/125PS) - Lynx, Removal and Installation).

Fuel Charging and Controls -
Turbocharger - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-
TDCi (103kW/140PS) - DW, Emission
Requirements: Stage IV - Turbocharger

S-MAX/Galaxy 2006.5 (02/2006-)

Description and Operation

Turbocharger with variable turbine geometry

Description

Turbocharger position sensor

Turbocharger housing

Seal

Connector

Connecting hose - oil return

Bracket

Banjo bolt

Oil line

Banjo bolt

To ensure an optimum torque curve, a Garrett turbocharger with variable turbine geometry
is used.

The movable guide vanes on the turbine wheel are adjusted by the turbocharger vacuum
canister by means of a connecting rod.

A position sensor is located centrally on the turbocharger vacuum canister; this forwards
the position of the guide vanes to the powertrain control module (PCM) as an input
variable.

The vacuum to the turbocharger vacuum canister is metered by the boost control solenoid
valve. The boost control solenoid valve is controlled by the PCM .

The bearings of the turbocharger are lubricated by the engine's oil circuit via a rigid oil pipe.

Item

Part Number

S-MAX/Galaxy 2006.5 (02/2006-)

Diagnosis and Testing

Special Tool(s)

General Equipment

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
vapor 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 or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

Hand Vacuum/Pressure Pump

416 - D001 (23 - 036A)

Fuel Pressure Gauge

310-053 (23-046)

Worldwide Diagnostic System (WDS) (418-
F224)

Mechanical

Electrical

Oil leak(s)

Air cleaner element

Air cleaner outlet pipe

Air cleaner intake pipe

Turbocharger oil supply or oil return tube

Turbocharger intake pipe

Turbocharger vacuum diaphragm unit

Turbocharger housing

Charge air cooler

Charge air cooler intake pipe and hose(s)

Charge air cooler outlet pipe and hose(s)

Wiring harness

Vane adjustment solenoid valve

PCM

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