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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 747 (Engine Controls - Pinpoint Tests - 6.0L Diesel (99P E-Series & 99P F450/550)) >> Pinpoint Test KA: Turbo Charger System Performance >> Test Procedure

Test Procedure

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  1. KA1 PRELIMINARY DIAGNOSIS 
    • Key off.
    • Perform a visual inspection.
    • Key on, engine off (KOEO)
    • Retrieve and record any continuous and on-demand DTCs.

    ARE ANY DTCS PRESENT? 

    Yes No
    For DTC P0299, P0478, P132B, P2262 or P2263, Go to  KA2.
    For all other DTCs, REFER to DIAGNOSTIC TROUBLE CODE (DTC) DESCRIPTIONS .    		 Go to  KA2.
  2. 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: Manifold Absolute Pressure (MAP) Sensor, Analog .
  3. KA3 CHECK THE ICP SENSOR FOR BIAS 
    • Key on, engine off.
    • Access the ICP PID.

    IS THE ICP PID VOLTAGE BETWEEN 0.18 AND 0.24 VOLTS (EARLY BUILD) OR 0.15 AND 0.35 (LATE BUILD)? 

    Yes No
    Go to  KA4. INSTALL a new ICP sensor.
  4. KA4 CHECK FOR INPUT SENSOR BIAS 

    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 diagnostics.
  5. KA5 CHECK THE TURBOCHARGER OPERATION BOOST 
    NOTE: Additional DTCs may set during the use of output control (OSC). Clear all the PCM and transmission control module (TCM) DTCs after the diagnostics are completed. Repeat the self-test to verify all DTCs are cleared.
    • Key ON, engine running.
    • Access the PCM and monitor the MGP, EGR_DC, RPM 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  KA6. Go to  KA7.
  6. KA6 CHECK THE TURBOCHARGER OPERATION BACK PRESSURE 
    • Key ON, engine running.
    • Access the PCM and monitor the, EBP_G, EGR_DC, RPM and VGTDC PIDs.
    • Access the PCM and control the EGRDC, RPM_DSD, and VGTDC PIDs.
    • Increase the commanded engine speed to 1,250 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.
    • Increase the VGT duty cycle to greater than 85%.
    • Record the EBP_G PID.
    • Decrease the VGT duty cycle to 0%.
    • Record the EBP_G PID.

    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  KA8. Go to  KA7.
  7. KA7 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 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 air.
    • Check the 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  KA9.
  8. KA8 CHECK THE VGT ACTUATOR STABILITY 
    NOTE: This test may cause a misfire or rough idle condition.
    • Apply the parking brake.
    • Place the transmission in PARK or NEUTRAL.
    • Turn the A/C and defroster OFF.
    • Key ON, engine running.
    • Clear the PCM DTCs.
    • Access the PCM and monitor the IPR, EBP, MGP, EGR_DC, and VGTDC 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:
      • 1500 RPM
      • 1800 RPM
      • 2000 RPM
      • 2200 RPM
      • 2500 RPM
      • 2800 RPM

    DO THE VGTDC, MGP, AND 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.
  9. KA9 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  KA10. Go to  AK2.
  10. KA10 CHECK THE VGT VANE OPERATION 
    • Key in OFF position.
    • Install the 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%.
    • 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 the appropriate FUEL CHARGING AND CONTROLS article.
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