Toyota
Ford Kuga
 Service Manual
Fuel Charging and Controls - Turbocharger- 2.5L Duratec (147kW/200PS) - VI5
Turbocharger

Special Tool(s) / General Equipment

Hand Vacuum/Pressure Pump 416 - D001 (23 - 036A)
Fuel Pressure Gauge 310-053 (23-046)
Ford diagnostic 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 crankcase vent 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. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

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
  • Boost control solenoid valve
  • Powertrain control module (PCM)

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. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

NOTE: The vacuum diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or renewed.

Symptom Possible Sources Action
Blue smoke with excessive turbocharger noise
  • Turbocharger compressor rubbing on housing walls.
  • Turbocharger turbine rubbing on housing walls.
  • Turbocharger bearings and oil seal(s).
  • Turbocharger oil supply tube blocked or damaged.
INSPECT the turbocharger for signs of damage. INSTALL a new turbocharger as necessary.

REFER to: Turbocharger (303- 04 Fuel Charging and Controls - Turbocharger - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Blue smoke without excessive turbocharger noise Turbocharger oil return tube blocked or damaged.Blue smoke without excessive turbocharger noise Check the oil return tube for blockage or damage, INSTALL a new oil return tube as necessary.
Poor engine performance Vacuum diaphragm unit vacuum line(s). CHECK all vacuum line(s) are installed and no signs of air leaks are present. REPAIR as necessary.
Charge air cooler system. CHECK the charge air cooler, charge air cooler pipes and charge air cooler hoses for leaks and obstructions.

REPAIR as necessary.

Air cleaner intake pipe. CHECK the air cleaner intake pipe for obstruction. REPAIR the necessary.
Unauthorized adjustment of the vacuum diaphragm unit actuator rod. The turbocharger boost pressure is factory set and must not be adjusted. CHECK the paint seal on the vacuum diaphragm unit actuator rod has not been broken. If the paint seal has been broken, INSTALL a new turbocharger.

REFER to: Turbocharger (303- 04 Fuel Charging and Controls - Turbocharger - 2.5L Duratec (147kW/200PS) - VI5, Removal and Installation).

Vacuum diaphragm unit actuator rod. CHECK the vacuum diaphragm unit actuator rod moves freely, If the vacuum diaphragm unit actuator rod does not move freely. CHECK for signs of damage or signs of foreign material. REPAIR as necessary.
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