Test Procedure

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Ford RV Cutaway, 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

KA1 PRELIMINARY DIAGNOSIS

Key in OFF position.
Carry out a visual inspection.
Key ON, engine OFF.
Record the freeze frame data.
Retrieve the continuous memory DTCs.
Carry out the KOEO and KOER self-test.

Are any DTCs present?

Yes	No
For DTCs P0299, P2262 or P2263, GO to KA2. For DTC P0478, GO to KA6. For all others, REFER to DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS .	GO to KA2.

KA2 CHECK THE MANIFOLD ABSOLUTE PRESSURE (MAP) SIGNAL ACCURACY

NOTE: Route the pressure gauge hose to the passenger compartment so it is not crimped and does not come in contact with any hot surface.

Inspect the MAP sensor hose and manifolds for damage, leaks, restrictions, and correct routing.
Disconnect the MAP sensor pressure hose from the sensor.
Install the pressure test adapter kit 014-00761 0-30 psi gauge between the MAP sensor and the pressure hose.
Access the PCM and monitor the MGP and EOT PIDs.
Allow the EOT to reach 70°C (158°F) and road test the vehicle.

Does the MGP PID match the actual gauge pressure?

Yes	No
GO to KA3.	GO to Pinpoint Test E .

KA3 CHECK THE ICP SENSOR FOR BIAS

Key ON, engine OFF.
Access the PCM and monitor the ICP_V PID.

Is the voltage between 0.15 - 0.35 V?

Yes	No
GO to KA4.	INSTALL a new ICP sensor. CLEAR the DTCs. REPEAT the self-test.

KA4 CHECK FOR INPUT SENSOR BIAS

Access the PCM and monitor the BARO, EGR_DC, EBP, MAF V and MAP PIDs.
Refer to REFERENCE VALUES for normal operating values.

Are the BARO, EGR_DC, EBP, MAF, and MAP PIDs within specifications and is the EBP PID value within 10.34 kPa (1.5 psi) of the MAP and BARO PID values?

Yes	No
GO to KA5.	REFER to the appropriate pinpoint test to continue sensor diagnosis.

KA5 CHECK THE EGR VALVE OPERATION

NOTE: Incorrect EGR valve operation may affect turbocharger diagnostics.

Check the EGR valve operation. Refer to EXHAUST GAS RECIRCULATION (EGR) POSITION TEST .

Is a concern present?

Yes	No
REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test.	GO to KA6.

KA6 CHECK THE TURBOCHARGER OPERATION BOOST

NOTE: Additional DTCs may set during the use of output state control (OSC). Clear all PCM and transmission control module (TCM) DTCs after the diagnostics have been completed. Repeat the self-test to verify all DTCs have been cleared.

Key ON, engine running.
Access the PCM and monitor the RPM, MGP, EGR_DC and VGTDC PIDs.
Access the PCM and control the EGRDC, RPM_DSD, and VGTDC PIDs.
Increase the commanded engine speed to 1,200 RPM using output state control. The calibration may limit the actual RPM between 1,150 and 1,200 RPM.
Decrease the EGR duty cycle to 0%.
Decrease the VGT duty cycle to 0%.
Record the MGP PID value.
Increase the VGT duty cycle to greater than 85%.
Record the MGP PID value.
Decrease the VGT duty cycle to 0%.
Record the MGP PID value.

Is the MGP PID below 3 kPa (0.44 PSI) at 0% VGT duty cycle and above 6 kPa (.87 PSI) at 85% VGT duty cycle?

Yes	No
GO to KA7.	GO to KA8.

KA7 CHECK THE TURBOCHARGER OPERATION BACK PRESSURE

Key ON, engine running.
Access the PCM and monitor the RPM, EBP_G, EGR_DC and VGTDC PIDs.
Access the PCM and control the EGRDC, RPM_DSD, and VGTDC PIDs.
Increase the commanded engine speed to 1,200 RPM using output state control. The calibration may limit the actual RPM between 1,150 and 1,200 RPM.
Decrease the EGR duty cycle to 0%.
Decrease the VGT duty cycle to 0%.
Record the EBP_G PID value.
Increase the VGT duty cycle to greater than 85%.
Record the EBP_G PID value.
Decrease the VGT duty cycle to 0%.
Record the EBP_G PID value.

Is the EBP_G PID below 5 kPa (0.73 PSI) at 0% VGT duty cycle and above 50 kPa (7.3 PSI) at 85% VGT duty cycle?

Yes	No
GO to KA9.	GO to KA8.

KA8 CHECK THE CHARGE AIR COOLER, AIR INTAKE AND EXHAUST SYSTEMS FOR LEAKS

Key in OFF position.
Disconnect the hose from the EP sensor.
Plug the exhaust pipe.
Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the EP hose.
Fill the exhaust system with smoke.
Pressurize the exhaust system with 20 PSI regulated shop air.
Disconnect the hose from the MAP sensor.
Inspect the MAP sensor hose and manifolds for damage, leaks, restrictions, and correct routing.
Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the MAP hose.
Fill the air intake system with smoke.
Pressurize the air intake system with 20 PSI regulated shop air.
Check air intake and exhaust systems for leaks.

Are any leaks present?

Yes	No
REPAIR the leaks. REFER to PERFORMANCE DIAGNOSTIC PROCEDURES if a driveability concern exists. CLEAR the DTCs. REPEAT the self-test.	GO to KA10.

KA9 CHECK THE VGT ACTUATOR STABILITY

NOTE: This test may cause misfire or rough idle condition.

Apply the parking brake.
Place the transmission in PARK or NEUTRAL.
Turn the A/C and defrost OFF.
Key ON, engine running.
Clear the DTCs.
Access the PCM and monitor the EBP, MGP, EGR_DC, VGTDC and IPR PIDs.
Access the PCM and control the EGRDC PID.
Decrease the EGR duty cycle to 0%.
Allow the IPR to stabilize.
Slowly press the accelerator pedal and hold for 5 seconds at each of the following RPMs:
- 1,500 RPM
- 1,800 RPM
- 2,000 RPM
- 2,200 RPM
- 2,500 RPM
- 2,800 RPM

Do the VGTDC, MGP, or EBP PIDs remain steady at all of the RPMs?

Yes	No
The turbocharger system is operating correctly. REFER to PERFORMANCE DIAGNOSTIC PROCEDURES . CLEAR the DTCs. REPEAT the self-test.	GO to AK7.

KA10 CHECK THE OPERATION OF THE VGT ACTUATOR

CAUTION: The VGT actuator valve is sensitive to contamination. All work areas must be clean before starting this procedure. Do not allow contamination to enter the valve ports, cam follower, or turbocharger housing. Handle the VGT actuator by the solenoid body only. Do not attempt to clean or wipe oil off the valve at this time. Do not let the valve come in contact with materials that could contaminate the valve mechanism.

Key in OFF position.
VGT Actuator connector disconnected.
Remove the VGT actuator from the turbocharger assembly.
VGT Actuator connector connected.
Key ON, engine OFF.
Access the PCM and control the VGTDC PID.
Apply light pressure to the cam follower (tip of the actuator), while commanding the VGT duty cycle and check for the internal valve movement.
Increase the VGT duty cycle to greater than 70%.

Is any internal valve cam follower movement present when the VGT duty cycle is increased?

Yes	No
GO to KA11.	GO to AK2.

KA11 CHECK THE VGT VANE OPERATION

Key in OFF position.
Install a VGT actuator in the turbocharger assembly.
Remove the pipe plug from the top of the VGT actuator housing, located near the oil supply tube.
Apply an index mark on the internal valve cam follower (tip of the actuator).
Key ON, engine running.
Access the PCM and control the VGTDC PID.
Increase the VGT duty cycle from 20% to greater than 85% in 10% steps.
Check the internal valve cam follower for movement at each step while increasing the duty cycle.

Is any internal valve cam follower movement present in each step when the VGT duty cycle is increased?

Yes	No
The turbocharger system is operating correctly. REFER to PERFORMANCE DIAGNOSTIC PROCEDURES . CLEAR the DTCs. REPEAT the self-test.	INSTALL a new turbocharger assembly. REFER to FUEL CHARGING AND CONTROLS - TURBOCHARGER .