303-04F Fuel Charging and Controls — Turbocharger 303-04F

SECTION : 303-04F Fuel Charging and Controls —

Turbocharger
VEHICLE APPLICATION : 2014 Falcon
CONTENTS PAGE
SPECIFICATIONS
Specification .........................................................................................................................303-04b-1
DESCRIPTION AND OPERATION
Turbocharger ........................................................................................................................303-04b-3
Boost Control .......................................................................................................................303-04b-4
Charge Air Cooler (Intercooler) ............................................................................................303-04b-5
Heatshielding .......................................................................................................................303-04b-5
DIAGNOSIS AND TESTING
Turbocharger ........................................................................................................................303-04b-6
Inspection and Verification .................................................................................................303-04b-6
Symptom Chart ..................................................................................................................303-04b-7
Pinpoint Tests ....................................................................................................................303-04b-8
REMOVAL AND INSTALLATION
Turbocharger ......................................................................................................................303-04b-11
Boost Pressure Sensor ......................................................................................................303-04b-14
Wastegate Control Solenoid (WCS) ..................................................................................303-04b-15
Charge Air Cooler (Intercooler) ..........................................................................................303-04b-15

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SPECIFICATIONS

NOTE:Oil threads with engine oil.

NOTE:Do not oil threads that require thread sealant
or thread locker.
Location Part Description Installation Lubrication Lower Upper Nominal
Number (Nm) (Nm) (Nm)
Manifold to Head W713247 BOLT Patch lock- no oiling required 50 53 55
M10x30
Manifold to Head W713246 BOLT Patch lock- no oiling required 50 53 55
(Lifting Eye) M10x35
Turbo to Manifold W713609 STUD Tri-lobe lock – no oiling required 28 32 30
M10x1.25x18
+ M10x12
Turbo to Manifold W708915 NUT M10 Deformed thread- no oiling 44 50 47
required
Dump pipe to W712418 BOLT Tri-lobe lock – no oiling required 22 26 24
Turbocharger
Dump Pipe braces W712418 BOLT Tri-lobe lock – no oiling required 14 18 16
to:
Dump pipe
upper
Dump pipe
lower
Dump Pipe braces V800153 BOLT Patch lock – no oiling required 24 28 26
to: M10x25
Engine block
upper
Engine block
lower
Heat shields to N605904 BOLT M8 Patch lock – no oiling required 17 24 20.5
exhaust manifold
Heat shields to W714210 BOLT Patch lock – no oiling required 24 28 26
dump pipe M10x16
Oil feed to BANJO Patch lock – no oiling required 22 26 24
turbocharger BOLT M12
Oil feed filter to 3R23- Banjo Patch lock – no oiling required 17 24 20.5
block 9P424-A adaptor and
filter
assembly
Oil feed filter nut to WR2T- Oil pressure Lubricate with oil 17 24 20.5
Banjo 6N637-A sender
adaptor M14
Oil return pipe to: W708347 BOLT M8x15 Patch lock – no oiling required 17 24 20.5
Turbocharger
Engine block
Coolant feed & BANJO Lubricate with oil 40 50 45
return to BOLT M14
turbocharger
Coolant feed & V890159 HOSE - 2.5 3.5 3
return clamp CLAMP
16-30mm

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SPECIFICATIONS (Continued)

Torque Specifications (Intercooler & Ducting)

Description Nm
Upper studs to crush tube (x2) 20r3
(Intercooler)
Lower bolts to Intercooler 20r3
Isolators (x2)
Upper and lower Intercooler 20r3
brackets to RGOR*
Screw hose clamps on air 2.2 -3.0
ducting pipes & hoses
RGOR* Duct (LH & RH) 10.5 r1.6
mounting hardware to RGOR*
Boost pressure sensor screw r0.3
Wastegate solenoid bracket r1.2
retaining screw
Cross-over duct nuts 10
RH RGOR* Duct mounting 20r3
bracket to battery tray (x2)
* Reinforced Grille Opening Reinforcement

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DESCRIPTION AND OPERATION

Turbocharger
Applicable for ALL turbo models.

Item Description
1 Coolant Supply Line
2 Oil Supply Line
3 Coolant Return Pipe
4 Oil Return Pipe
The turbocharger consists of two elements, a turbine
and a compressor both installed on a single shaft and
contained within housings.
The turbocharger bearings are supplied oil from the
engine via the oil supply tube. This is returned to the
oil pan via the oil return pipe.
The turbocharger housing also receives coolant from
the engine cooling system, to assist with turbocharger
Item Description
cooling.
1 Exhaust manifold
The turbine element of the turbocharger is mounted
on the exhaust manifold and uses the energy of the 2 Turbine side of turbocharger
exhaust gas to drive the compressor. The compressor 3 Compressor side of turbocharger
feeds air to the engine via the intercooler.

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DESCRIPTION AND OPERATION (Continued)

Boost Control BPS Specification

The turbocharger is governed by means of a Absolute Pressure (kPa) Signal Voltage (V)
wastegate valve. The wastegate valve diverts some of 10 0.22
the exhaust gas past the turbine and therefore 50 0.95
regulates the speed of the turbine. The wastegate
valve is controlled by a pressure operated actuator. 100 1.88
The actuator incorporates a diaphragm, and uses 150 2.8
regulated air pressure to control the wastegate. This 200 3.7
actuator is preset during manufacture and must not be
tampered with. The PCM uses the BPS output voltage to control
boost pressure, dependent upon engine load,
temperature and RPM. The control system increases
engine intake pressure by diverting excess pressure
away from the wastegate actuator through the
wastegate solenoid valve. The solenoid valve is
controlled by the PCM’s TURBO output.

CONNECTIONS AT PCM
Pin B44 Boost Pressure Sensor
(BPS) Signal
Pin B33 BPS Signal Return
(SIGRTN)
Pin B19 TURBO
Pin B45 Vehicle Reference
The air pressure to the actuator diaphragm is Voltage (VREF)
regulated by use of a boost pressure sensor (BPS)
and a wastegate control solenoid (WCS). Intake air pressure is further controlled by a blow-off
valve, which dumps excess pressure into the low
The boost pressure sensor is located on the ETB
pressure side of the intake system when the throttle is
duct.
closed.
The wastegate control solenoid is mounted
The blow-off valve is actuated by intake manifold
underneath the fuse box.
pressure, via a rubber hose from the intake manifold.
The blow-off valve is situated in the cross-over duct
on top of the engine.

Item Description
1 Boost Pressure Sensor
The BPS measures the absolute pressure of the
pre-throttle intake system for cruise control and
wastegate control strategy. The pressure sensing
element in the BPS employs a piezo resistive sensor
that outputs a voltage proportional to absolute
pressure.

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DESCRIPTION AND OPERATION (Continued)

Charge Air Cooler (Intercooler)

The Charge Air Cooler (CAC) is an air-to-air cooler.
The compressed air from the turbocharger flows
through the cooler, and is cooled by outside air
flowing over the vanes of the CAC.
The lower temperature of the charge air increases its
density, so giving improved engine efficiency and
power.
The CAC is mounted in front of the radiator with four
rubber isolated mounts.

Heatshielding
Three heatshields cover the exhaust manifold and the
turbocharger, to protect surrounding engine bay
components from heat damage.

Item Description
1 Rear exhaust manifold heatshield
2 Front exhaust manifold heatshield
3 Steering Shaft / Engine mount heatshield

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DIAGNOSIS AND TESTING

Turbocharger
Inspection and Verification
NOTE: It is normal for a small amount of combustion
gas to pass into the crankcase. These ’blow-by’
gases are scavenged into the air intake system
through the positive crankcase ventilation (PCV)
system.
Some engine oil, in the form of a vapour is carried into
the air intake system with the blow-by gases. This
means that a small amount of 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 the following obvious signs of
mechanical and electrical damage:

Visual Inspection Chart

Mechanical Electrical
Oil leak(s) Wiring harness
Air cleaner element Electrical connector(s)
Air cleaner outlet pipe PCM
Air cleaner intake pipe Boost Pressure
Turbocharger oil Sensor
supply or oil return Wastegate Control
tube Solenoid
Turbocharger coolant
supply or return tube
Wastegate valve and
actuator
Turbocharger
housings
Turbocharger turbine
wheel blades
Turbocharger
compressor wheel
blades
Charge Air Cooler
Ducting to and from
the Charge Air Cooler
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 Symptom Chart.

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DIAGNOSIS AND TESTING (Continued)

Symptom Chart
NOTE: The wastegate actuator diaphragm unit is a fixed part of the turbocharger and cannot be adjusted or
renewed.

Condition Source Action

Blue smoke with excessive Turbocharger compressor rubbing on Go to PinPoint Test A.
turbocharger noise housing walls.
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.

Poor engine performance Wastegate control valve vacuum CHECK all vacuum line(s) are installed
line(s). and no signs of air leaks are present.
REPAIR as necessary.
Unauthorized adjustment of the The turbocharger boost pressure is
wastegate control valve actuator rod. factory set and must not be adjusted.
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

Wastegate valve actuator rod. CHECK the wastegate valve actuator

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

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DIAGNOSIS AND TESTING (Continued)

Pinpoint Tests

PINPOINT TEST A : NOISY TURBOCHARGER WITH BLACK OR BLUE EXHAUST SMOKE

Test Step Result / Action to Take

A1 INSPECT THE TURBOCHARGER COMPRESSOR VANES

FOR DAMAGE
Carefully disconnect the turbocharger compressor inlet air supply duct Yes
from the turbocharger. Go to A2
and install a new turbocharger. REFER to
Inspect the turbocharger compressor wheel blades for damage.
Removal and Installation - Turbocharger. TEST
Is there visible damage to the compressor wheel? the system for normal operation.

No
Go to A3

A2 CHECK FOR FOREIGN MATERIAL IN THE INTAKE AIR

SYSTEM COMPONENTS
Check the intake air system components for signs of foreign material. Yes
CLEAN the intake air system components.
Are there any signs of foreign material?
No
Go to A4

A3 CHECK THE TURBOCHARGER BEARINGS FOR

EXCESSIVE MOVEMENT

NOTE: A small amount of movement in the bearings is normal. Yes

Go to A4
Make sure the turbocharger rotor spins freely within the housing.
While slowly turning the rotor assembly by hand, push the shaft No
radially and axially. INSTALL a new turbocharger.
REFER to Removal and Installation -
Does the rotor spin freely within the housing? Turbocharger.
TEST the system for normal operation.

A4 CHECK THE TURBOCHARGER OIL SUPPLY TUBE FOR

BLOCKAGE

NOTE: New sealing washers should be installed when refitting the oil Yes
pipe. INSTALL a new turbocharger oil supply pipe
and/or banjo bolt.
Disconnect the oil supply tube from the turbocharger. TEST the system for normal operation.

Attach a small piece of known good hose to the oil supply tube and No
gently blow down the hose. Go to A5
INSPECT the banjo bolt and turbo oil gallery for signs of blockage or
oil clotting.
Are there any signs of blockage?

A5 INSPECT THE TURBOCHARGER TURBINE WHEEL FOR

DAMAGE
Remove the exhaust pipe and the dump-pipe from the turbocharger. Yes
INSTALL a new turbocharger. REFER to
Inspect the turbine wheel blades for damage. Removal and Installation - Turbocharger.
Are there any signs of damage? SOURCE and rectify the cause of the damage to
the turbine blades.
TEST the system for normal operation.

No
Go to A1

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DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B : BLUE EXHAUST SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE

Test Step Result / Action to Take

B1 CHECK THE TURBOCHARGER OIL RETURN PIPE

NOTE: New sealing gaskets should be installed when refitting the oil Yes
return pipe. Go to 303-01A for further blue smoke
diagnostics.
Disconnect the turbocharger oil return tube from the turbocharger and
from the engine sump No
INSTALL a new turbocharger oil return tube.
Remove the turbocharger oil return tube. TEST the system for normal operation.
Check the turbocharger oil return tube for a blockage or signs of
damage.
Is the turbocharger oil return tube OK?

PINPOINT TEST C : POOR ENGINE PERFORMANCE

Test Step Result / Action to Take

C1 CHECK THE WASTEGATE ACTUATOR CONTROL
HOSE
Remove the wastegate actuator control hose. Yes
INSTALL a new wastegate actuator control
Check that the hose has no cracks or holes, and that it is not blocked. hose.
Is the hose damaged? TEST the system for normal operation.

No
Go to C2

C2 CHECK THE WASTEGATE ACTUATOR DIAPHRAGM

FOR LEAKS

NOTE: The wastegate control actuator is factory set and must not be Yes
adjusted or modified. If the wastegate control actuator is not operating Go to C3
correctly, the complete turbocharger assembly must be replaced.
No
Connect one end of the wastegate actuator control hose to the INSTALL a new turbocharger.
wastegate actuator. REFER to Removal and Installation -
Turbocharger
Connect the other end of the wastegate control actuator hose to a TEST the system for normal operation.
hand pressure pump.
Using the hand pressure pump apply 45-50 kPa to the wastegate
actuator.
Does the wastegate actuator rod move and hold its new position
until the pressure is released?

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DIAGNOSIS AND TESTING (Continued)

Test Step Result / Action to Take

C3 CHECK THE WASTEGATE CONTROL SOLENOID

NOTE: The wastegate control solenoid is factory set and must not be Yes
adjusted. REPLACE the wastegate control solenoid.
REFER to Removal and Installation - Wastegate
NOTE: If a fault develops in the turbo wastegate control system, a Control Solenoid.
standby function is carried out. The wastegate solenoid is forced fully open TEST the solenoid.
(0% duty cycle) allowing minimum mechanical boost to be delivered. If the
boost pressure is still higher than desired, torque-limiting by cylinder No
cut-out will occur. The appropriate trouble code will be logged in memory Go to C4
for retrieval during Self Test mode.

Connect a IDS tester to the diagnostic connector.

Check for Diagnostic Trouble Codes at:
- Key-On-Engine-Off (KOEO)
- Key-On-Engine-Running (KOER)
- Engine Running (cont)
Is the solenoid operation faulty?

C4 CHECK THE BOOST PRESSURE SENSOR

NOTE: The Failure Mode Effects Management (FMEM) strategy will, in Yes
most cases, ensure reasonable operation of the vehicle in the event of a REPLACE the boost pressure sensor.
BPS failure. If the BPS signal is not within the normal operating range, the REFER to Removal and Installation - Boost
PCM will substitute a default value for pre-throttle absolute pressure and Pressure Sensor.
use MAP for boost control. The appropriate trouble code will be logged in TEST the sensor.
memory for retrieval during Self Test mode.
No
Connect a WDS tester to the diagnostic connector. Go to C5

Check the Parameter Identification (PID) value of the BPS. At

Key-On-Engine-Off (KOEO) the value should be between 1.8 - 2.0
Volts.
Is the PID value within the specified limits?

C5 CHECK THE BOOST PRESSURE

NOTE: The boost pressure is factory set and must not be adjusted. Yes
Go to C6
Start and run the engine until normal operating temperature is
achieved. No
REPLACE the boost pressure sensor.
Connect a WDS tester to the diagnostic connector. REFER to Removal and Installation - Boost
Run the engine at idle and observe the Parameter Identification (PID) Pressure Sensor.
value of the BPS. The value should be between 1.8 - 2.0 Volts. TEST the sensor.

Is the PID value within the specified limits?

C6 CHECK THE CHARGE AIR COOLER AND DUCTING

Remove the air ducting that runs to and from the charge air cooler. Yes
REFER to Removal and Installation - Charge Air Cooler. Unblock or replace components as required.
REFER to Removal and Installation - Charge Air
Inspect the components for cracks, leaks or blockages. Cooler.
Remove the charge air cooler. REFER to Removal and Installation - TEST the system for normal operation.
Charge Air Cooler.
No
Inspect the cooler for cracks, leaks or blockages. TEST the fuel system. REFER to Section
Are any blocked or damaged components evident? 310-00.

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REMOVAL AND INSTALLATION

Turbocharger 5. Disconnect the water inlet tube from the

turbocharger.
Removal 1. Discard the sealing washers.
All vehicles
1. Disconnect the battery ground cable. For
additional information, refer to Section 414-01.
2. Remove the fresh air duct from the turbocharger.
1. Unscrew the hose clamps.
2. Remove the pipe.

6. Disconnect the water outlet tube from the

turbocharger.
1. Discard the sealing washers.

3. Detach the charge air cooler intake duct from the

turbocharger.
1. Unscrew the hose clamp.
2. Remove the duct.

4. Disconnect the HEGO sensor wiring connector at

the flex plate.

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REMOVAL AND INSTALLATION (Continued)

7. Disconnect the oil supply tube from the 11. Remove and discard the dump pipe upper & lower
turbocharger. pencil brace bolts from dump pipe and engine
1. Discard the sealing washers. block.
8. Disconnect the oil return tube from the
turbocharger.
1. Discard the gasket.

12. Remove and discard the four turbocharger to

manifold nuts.
13. Remove turbocharger and dump-pipe as a
complete assembly.
Item Description
1 Coolant Supply Line
2 Oil Supply Line
3 Coolant Return Pipe
4 Oil Return Pipe
9. Remove the rear turbocharger heatshield:
1. Remove and discard the three heat shield
bolts.
2. Remove the rear turbocharger heat shield.

14. Remove and discard the turbocharger to dump

pipe studs.
15. Remove the dump-pipe:
1. Remove and discard the five retaining bolts.
2. Discard the gasket.

10. Disconnect the exhaust catalyst pipe from the

dump-pipe.

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REMOVAL AND INSTALLATION (Continued)

Installation 5. Connect the exhaust catalyst to dump-pipe.

All vehicles 1. Use new studs.
2. Use new catalyst pipe nuts.
NOTE: Install a new dump-pipe gasket.
3. Torque nuts to specifications.
NOTE: Install a new oil return line gasket (x2).
NOTE: Install new oil supply line sealing washers
(x2).
NOTE: Install new coolant supply line gaskets (x2).
NOTE: Install new coolant return line gaskets (x2).
1. Refit the dump-pipe to the turbocharger.
1. Fit a new dump-pipe gasket.
2. Use new dump pipe to turbocharger bolts -
torque to specification.

6. Connect the oil return tube to the turbocharger.

1. Install a new oil return line gasket.

2. Ensure bolt holes on exhaust manifold flange are

re-tapped to M10 x 1.5 - 6g
3. Refit the turbocharger and dump pipe onto the
exhaust manifold.
1. Fit new turbocharger studs to the exhaust
manifold - torque to specification.
2. Place the turbocharger and dump pipe onto Item Description
the studs. 1 Oil supply line
3. Fit new turbocharger nut to the studs - torque 2 Oil return line
to specification.
NOTE: There is no gasket between the
exhaust manifold and turbocharger.
4. Use new bolts to fit the upper and lower dump
pipe braces to the dump pipe and engine
block - torque to specification.
4. Reconnect the HEGO sensor wiring.

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REMOVAL AND INSTALLATION (Continued)

7. Connect the coolant outlet tube to the 10. Connect the charge air cooler intake pipe.
turbocharger.
1. Install a new coolant outlet line sealing CAUTION: Make sure that the inside of
washers - torque banjo bolt to specification. the charge air cooler intake pipe is clean and
free from any residue as this will reduce the
installation grip of the pipe to the charge air
cooler. Failure to follow this instruction may
result in engine damage.
1. Install the pipe to the turbocharger.
2. Refit the two hose clamps and tighten to
specification.

8. Connect the coolant inlet line to the turbocharger.

1. Install a new coolant inlet line sealing washers
- torque banjo bolt to specification.

11. Install the fresh air inlet duct to the turbocharger.

1. Install the pipe duct.
2. Tighten the hose clamps to specification.

9. Install the rear turbocharger heat shield.

1. Use new bolts to fit the rear heat shield, hand
start all bolts then torque to specification.

12. Connect the battery ground cable. For additional

information, refer to Section 414-01.
13. Start engine and check all connections for
oil/water/air leaks.
Boost Pressure Sensor
Removal
1. Disconnect the wire harness from the BPS
connector.
2. Undo the retaining bolt.

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REMOVAL AND INSTALLATION (Continued)

3. Gently pull the sensor out vertically from the 3. Connect the hose that runs from the WCS to the
plastic duct. wastegate actuator on the turbocharger.
4. Connect the hose that runs from the turbocharger
compressor to the WCS.
5. Reconnect the harness to the WCS.
Charge Air Cooler (Intercooler)
Removal
1. Remove bumper and grille, Refer Section 501-19
of this workshop manual.
2. Undo the hose clamps and disconnect the
inlet/outlet tube that runs from the intercooler to
the adjoining ducts.
3. Remove the bolts holding the intercooler to the
plastic reinforced grille opening reinforcement
Installation (RGOR)
1. Push the new BPS into the plastic duct. 4. Remove the intercooler and brackets together.
2. Refit the retaining bolt and tighten. 5. Remove the nuts holding the intercooler bracket
3. Reconnect the harness to the BPS. to the intercooler.

Wastegate Control Solenoid (WCS)

Removal
1. Disconnect the wire harness from the WCS
connector.
2. Disconnect the hose that runs from the
turbocharger compressor to the WCS.
3. Disconnect the hose that runs from the WCS to
the wastegate actuator on the turbocharger.
4. Undo the retaining bolt.
5. Withdraw the wastegate control solenoid.

Item Description
1 Hose WCS to turbo compressor
2 WCS electrical connection
3 Hose turbocharger actuator to WCS
4 Wastgate control solenoid (WCS)
Installation
1. Fit the wastegate control solenoid into position.
2. Refit the retaining bolt and tighten.

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REMOVAL AND INSTALLATION (Continued)

6. Remove the isolators and crush tubes from the

intercooler ends.

Item Description
1 Cool air to intake manifold inc BPS (ETB
duct)
2 Cool air ducting
3 Hot air ducting
4 Cool air hose from intercooler
5 Intercooler
6 Intercooler mounting brackets
Installation
1. Installation is the reversal of the removal
procedure.
2. Check all connections to ensure there are no
airleaks.

Version:2014 Falcon Workshop Manual