david moore

just a quick check guide on turbo x type

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turbo, Fuel Charging and Controls - Turbocharger - Turbocharger
Diagnosis and Testing
Overview
For information on the operation of the turbocharger:
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger, Description and Operation).
Inspection and Verification
• WARNINGS:
The following tests may involve working in close proximity to hot components. Make sure adequate protection is used. Failure to
follow this instruction may result in personal injury.
The turbocharger can continue to rotate after the engine has stopped. Do not attempt to check the turbocharger until one minute has
elapsed since the engine was switched off. Failure to follow this instruction may result in personal injury.
1. Verify the 1. customer concern.
2. 2. Visually inspect for obvious mechanical or electrical faults.
Visual inspection chart
Mechanical Electrical
Intake air system
Hose(s)/hose connections
Turbocharger
General engine condition.
Circuit(s)
Electrical connections and harnesses
Manifold absolute pressure and temperature (MAPT) sensor
Turbocharger actuator
Engine control module (ECM)
Symptom chart
Symptom Possible source Action
Poor performance
(off-boost)
Low/Contaminated
fuel
Restricted intake air
system
General engine
condition
Engine control
module (ECM) failure
Check the fuel level and condition. Draw off approximately 1 ltr (2.11 pints) of fuel and allow
to stand for 1 minute. Check to make sure there is no separation of the fuel indicating water
or other liquid in the fuel. Check the intake air system for restriction. Check the engine
condition, compressions, etc. if there are indications of a mechanical fault. Check for DTCs
indicating a module fault. Refer to the warranty policy and procedures manual if a module is
suspect.
No boost Electrical
connections and
harnesses
Restricted intake air
system
Charge air cooler
restricted/leaking
Turbocharger
actuator failure
Turbocharger failure
Engine control
module (ECM) failure
Check the electrical connections and harnesses. Check the intake air system for
restriction/leakage. Check the turbocharger actuator and circuit. Refer to the electrical guides.
Check the turbocharger for wear. Disconnect the turbocharger intake and outlet pipework and
turn the turbocharger by hand. Any roughness indicates a fault. Check any up and down
movement in the turbocharger shaft. Excessive movement indicates a fault. If in doubt,
compare the suspect unit with a new turbocharger. Check for DTCs indicating an actuator or
module fault. Refer to the warranty policy and procedures manual if a module is suspect.
No
boost/excessive
noise
Turbocharger failure Disconnect the turbocharger intake and outlet pipework and turn the turbocharger by hand.
Any roughness indicates a fault. Check any up and down movement in the turbocharger shaft.
Excessive movement indicates a fault. If in doubt, compare the suspect unit with a new
turbocharger.
For a complete list of all diagnostic trouble codes that could be logged on this vehicle. REFER to: Electronic Engine Controls (303-14B
Electronic Engine Controls - 2.0L Duratorq-TDCi/2.2L Duratorq-TDCi (110kW/150PS) - Puma, Diagnosis and Testing).
Diagnostic Trouble Codes (DTC) Relating to Turbocharger Issues
DTC Description
P2263 Turbocharger/Supercharger Boost System Performance
. This vehicle may not feature all of the components listed.
. This DTC may be caused by:
. Damaged or disconnected vacuum hose. Check for air leaks at turbocharger. Vanes on the turbocharger sticking closed. Turbocharger
defective.
. Or
. Fault reported by the rotary electronic actuator.
. This DTC may be caused by:
. CAN communication BUS fault. Rotary electric actuator. Low battery voltage. Turbocharger defective.
P132A Turbocharger/Supercharger Boost Control A Electrical
. Fault reported by the rotary electronic actuator.
. This DTC may be caused by:
. Rotary electric actuator. Renew the variable geometry turbocharger.
P132B Turbocharger/Supercharger Boost Control A Performance
. Fault reported by the rotary electronic actuator.
. This DTC may be caused by:
. Faulty turbocharger, mechanism may be sticking.
. Rotary electric actuator. Renew the variable geometry turbocharger.
P132CTurbocharger/Supercharger Boost Control A Voltage
. Fault reported by the rotary electronic actuator.
DTC Description
. This DTC may be caused by:
. Low battery voltage. Check the condition of the battery. Check the wiring and the appropriate fuse. High battery voltage. Check the
battery charging system.
P138DTurbocharger/Supercharger Boost Control A Temperature Too High
. Fault reported by the rotary electronic actuator.
. This DTC may be caused by:
. Leaking exhaust system. Engine overheat condition.
. Rotary electric actuator. Renew the variable geometry turbocharger.
P179ACAN Engine Control Module (ECM)/Turbocharger Boost Control A Actuator Circuit Malfunction
. Fault reported by the rotary electronic actuator or powertrain control module (PCM).
. This DTC may be caused by:
. Controller area network (CAN) communication BUS fault. Check CAN wiring/CAN Network is functioning. If CAN wiring/CAN Network is
functioning but the vehicle has loss of power, then renew the variable geometry turbocharger.
Diagnostic Procedure
Log any concerns raised by the customer regarding the fault with the vehicle – Discuss with workshop supervisor/receptionist
Check logged DTC - Rectify concern
Check the vehicle Integrated Diagnostic System (IDS) DVD patch file calibration – Update to the latest level
Quick Check List
Listen for unusual mechanical noise and watch for vibration
Listen for a high pitched noise (it can indicate air or gas leaks)
Listen for noise level cycling. It can indicate a restriction in the air cleaner or ducting
Inspect for missing or loose nuts, bolts, clamps and washers
Inspect for loose or damaged intake and exhaust manifolds and their ducting and clamps
Inspect for damaged or restricted oil supply and drain lines
Inspect for cracked or deteriorating turbocharger housings
Inspect for external oil leakage; external deposits (indicates air, oil, exhaust or coolant leakage)
Inspect for a restricted air filter
Check the turbocharger variable vane actuator arm for normal operation, free movement and damage
Point Health Check:
1. Turbocharger Data Plate:
- 1. Check the turbocharger data stamped on the compressor housing. Record assembly number, serial number and turbocharger
type
- 2. Ensure turbocharger type and assembly number are correct for the engine application
2. Compressor/Turbine Wheel (Turbocharger System Trouble Shooting):
-
WARNING: Ensure wheels have stopped rotating before handling
CAUTION: Never attempt to straighten blades. If any bent blades are detected replace the turbocharger
• NOTE: Root cause of failure should be identified to eliminate repeat failure. Please make reference to section 'Turbocharger
Trouble Shooting'
1. Check for cracked/bent or damaged compressor (impeller) blades - Replace turbocharger if damaged
- 2. Check for cracked/bent or damaged turbine blades - Replace turbocharger if damaged
3. Compressor/Turbine Housing:
-
• NOTE: Removal of the compressor or turbine housings will invalidate the Warranty
1. Check for foreign objects, damage, or for excessive oil at the compressor housing air inlet and outlet
- 2. Check for foreign objects, damage, or for excessive oil at the turbine housing exhaust inlet and outlet
4. Turbocharger Bearing Clearances:
-
• NOTE: If there is contact between compressor/turbine wheel and housing - Replace the turbocharger
1. Gently rotate the compressor wheel and check for smooth operation
- 2. Gently hold to one side and rotate the compressor wheel and check for smooth operation
5. Bearing Housing:
-
• NOTE: Removal of the compressor or turbine housings will invalidate the Warranty
1. Check oil feed and drain port for loose fasteners, adapters or damage to flanges, housing faces or threads which may cause
leakage
- 2. Check for loose or broken turbine and compressor housing fasteners. If mounting flanges are damaged, replace or tighten
(torque to manufacturer's specification)

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I would have been ringing my mechanic before the 10th line:w00t:

Peter.

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we had a chap at work who was told his turbo was knackered! and would cost over £600 +vat .... but we checked it out with this list and it turned out to be the actuator !   cost of repair £82   and we fitted it in half an hour. guess what though weeks later he sold the car....

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