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TECHNICAL SERVICE BULLETIN
reissue No.46/2008
11 August 2008
Subject/Concern: Loss of power; Failure of the turbocharger
Model:
Focus 2004.75 (07/2004–)
Assembly Plant: Valencia
Assembly Plant: Saarlouis
Engine: 1.6L Duratorq-TDCi (DV) Diesel(06/2003–)
C-MAX 2003.75 (06/2003–)
Assembly Plant: Valencia
Assembly Plant: Saarlouis
Engine: 1.6L Duratorq-TDCi (DV) Diesel
Markets: All
Section: 303-04
Summary
Should a customer experiences a loss of power and by following the relevant workshop manual procedure on FordEtis you find a failed turbocharger as the root cause with clear damage to the turbocharger (turbine/compressor wheels damaged or turbo shaft broken), the following procedure needs to be carried out to prevent reoccurrence of the failure.
cautionCAUTION: It is important to complete each step of this service instruction as directed. Failure to do so may result in misdiagnosis and failure to address the customers concern.
Parts Required
Description Finis Code Quantity
Turbocharger - 1.6L Duratorq-TDCi (DV) diesel (90 PS) 1 523 337 1
Turbocharger - 1.6L Duratorq-TDCi (DV) diesel (110 PS) 1 479 055 1
Oil supply tube - 1.6L Duratorq-TDCi (DV) diesel (90 PS) 1 479 840 1
Oil supply tube - 1.6L Duratorq-TDCi (DV) diesel (110 PS) 1 479 839 1
Oil return line - 1.6L Duratorq-TDCi (DV) diesel (90 PS) 1 483 832 1
Oil return line - 1.6L Duratorq-TDCi (DV) diesel (110 PS) 1 483 831 1
Turbocharger oil feed pipe banjo bolt with filter 1 450 265 2
Oil supply tube union copper washer 1 232 215 6
Oil filter 1 359 941 2
Oil filter gasket 1 145 944 1
Oil pick up tube (including oil pick up tube retaining bolts (3 off)) 1 483 825 1
Seal vacuum pump 1 355 031 2
Catalytic converter to turbocharger clamp 1 474 828 2
Exhaust gasket 1 152 194 -
Gasket oil cooler and filter assembly 1 145 946 1
Turbocharger outlet pipe (If Required) 1 439 410 1
Remove, Check And Install Parts:
Materials
Name Specification
Formula E Engine Oil SAE (5W-30) WSS-M2C913-B
Silicone Sealer
General Equipment
Brake cleaner
Several improvements have been implemented in production to prevent soot in the oil.
Service Instruction
Removal
3. Remove the air cleaner outlet hose.
* Detach the air cleaner outlet hose.
* Disconnect the positive crankcase ventilation (PCV) hose quick release coupling.
4. Remove the brake vacuum pump.
* Remove and discard the brake vacuum pump seals.
Vehicles with DPF only
6. Remove the cooling fan motor and shroud.
7. Remove the turbocharger.
8. Remove the oil cooler and filter assembly.
* Remove the oil filter
9. Remove the oil supply tube from the cylinder block.
* Discard the oil supply tube and oil supply tube union copper washers.
10. Remove the oil pick up tube.
Check the following removed parts for metallic particles/debris - Examples of failed parts
1. Check the following removed parts for metallic particles/debris.
1. Turbocharger oil feed pipe
heck the following removed parts for metallic particles/debris - Examples of failed parts
1. Check the following removed parts for metallic particles/debris.
1. Turbocharger oil feed pipe banjo bolt with filter
2. Turbocharger oil return line (return line fully opened for clarification)
3. Oil cooler and filter assembly
4. Oil pick up tube
5. Oil filter
6. Brake vacuum pump
* If there are any residues of debris (metallic particles) inside the system (see examples of failed parts – please compare with yours), go to next step.
Install cleaned and new parts
1. Thoroughly clean the oil cooler and filter assembly at the corresponding engine side with brake cleaner and dry with compressed air.
2. Install the oil cooler and filter assembly with new gasket and oil filter
* Torque: 10 Nm
* Install a new oil return line to the oil cooler and filter assembly
3. Thoroughly clean the brake vacuum pump with brake cleaner, dry with compressed air and install new seals
Install a new oil pick up tube
* Thoroughly clean the oil pan with brake cleaner and dry with compressed air.
5. Remove the charge air cooler and drain off all the oil and metallic particles that remain inside.
6. Check the turbocharger outlet pipe for any damages.
* Especially on vehicles build before 05/2006 (build code 6J) a crack may be visible in the turbocharger outlet pipe. If damaged, install a new turbocharger outlet pipe (see Parts Required).
7. Visually inspect the following parts for obvious signs of damage, air restriction or contamination:
* Air cleaner element
* Air cleaner outlet hose
* Air cleaner intake hose
* Thoroughly clean these parts if required.
* Install a new turbocharger outlet hose
9. Install a new oil supply tube with a new lower banjo bolt with filter (see Parts Required).
* Thoroughly clean the upper banjo bolt before installation with brake cleaner and dry with compressed air.
* Install new oil supply tube union copper washers (see Parts Required).
10. NOTE: Do not install the oil return line to the turbocharger and the air cleaner outlet hose at this stage.
To install all remaning parts, reverse the removal procedure.
11. Fill the engine with engine oil.
Measure the volume of oil flow after the installation of the new parts
1. Install a longer oil return line (locally procured) to the turbocharger and feed into a suitable container (charge air cooler intake pipe removed for clarity).
* Install the air cleaner outlet hose.
* Start the engine and let running at idle. After 60 seconds switch off the engine and measure the volume of oil in the container. The quantity of oil collected in 60 seconds of uninterrupted flow should be higher than 0.3 liter.
1. cautionCAUTION: Ensure that the engine does not run below min. of oil level.
* Repeat the test 2 or 3 times to confirm the oil flow is correct. If the volume is NOT within specification call the Prior Approval Hotline (depending on market) for further actions. Prior approval MUST be obtained before a further repair is done.
3. Drive the vehicle (30-40 km).
Change the engine oil and filter again.