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

Turbocharger(s)

CAUTION: Do not switch off the engine while it is running at high speed. If the engine is switched off while it is running at high speed, the turbocharger will continue to run after the engine oil pressure has already dropped to zero. This will cause premature wear in the turbocharger bearings.

A TC consists of an exhaust turbine located in the exhaust gas flow, this turbine is connected to a compressor by a shaft. The turbine is made to rotate by the exhaust gas flow from the engine and thus drives the compressor. The compressor increases the pressure in the engine intake tract so that a greater mass of air enters the cylinder during the intake stroke.

The turbine housing of the TC is integrated into the exhaust manifold. This construction offers thermodynamic advantages compared with the usual construction, the maximum exhaust temperature is up to 1050C.

The maximum boost pressure is 0.65 bar.

The exhaust manifold is secured to the exhaust side of the cylinder head with 12 self-locking nuts.

The exhaust manifold gasket is a multi-layer steel gasket and cannot be reused. In order to compensate for the thermal expansion of the exhaust manifold, the flange of the TC is provided with two grooves.

The TC and the exhaust manifold are joined by a hose clip. The hose clip must not be loosened or removed. The TC and the exhaust manifold are not available as separate replacement parts, exchange is only possible as a complete unit.

The turbocharger heat shield is secured to the exhaust manifold by four bolts. Two of the bolts have spring washers underneath their heads.

During removal, make a note of the installation location of the spring washers to refer to during installation.

The recirculated air valve is built into the TC housing and cannot be changed.

The Ford diagnostic unit can test the operation of the wastegate control valve using actuator diagnosis.

The boost pressure regulator is set in the factory.

Adjustments to the boost pressure regulator must never be attempted. A red colored seal is applied to the adjustment nut of the operating rod, in order to monitor the factory setting of the boost pressure.

The bearings of the TC are lubricated with engine oil. The engine oil passes from the cylinder block through the oil supply pipe to the TC. The oil is returned to the oil pan through the oil return pipe, The TC is cooled by the engine coolant circuit.

When installing hoses and lines, make certain that their ends are free of oil residues and dirt.

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