Test KA: Turbocharger System Performance: Testing
WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
The Powertrain Control Module (PCM) harness connectors must be properly seated and the connector latch properly attached to eliminate possible driveability concerns or a no-start condition. Installing PCM connectors on an angle may cause a bad connection, misdiagnosis and damaged components. Install the connector on where the lever pivots and seats itself. Apply light pressure to get the connector into position on the PCM lever to fully seat the connector.
NOTE:
When the PCM engine harness connector is disconnected additional DTCs will be set. All DTCs must be cleared before returning the vehicle to service.
- 1) Preliminary Diagnosis
Key off. Perform a visual inspection. Connect the scan tool. Key on, engine off. Perform the KOEO ON-DEMAND SELF-TEST under QUICK TEST. Verify EGR operation. Are any DTCs present? If yes, for DTC P132B, P2262 or P2263, go to next step. For all other DTCs, see DIAGNOSTIC TROUBLE CODE DEFINITIONS . If no, go to next step. - 2) Check The Manifold Absolute Pressure (MAP) And Barometric Pressure (BARO) Signal Accuracy
Inspect the MAP sensor hose and manifolds for damage, leaks, restrictions and correct routing. Disconnect the MAP sensor 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? If yes, go to next step. If no, go to TEST E: MANIFOLD ABSOLUTE PRESSURE SENSOR . - 3) Check The ICP Sensor For Bias
Key on, engine off. Using scan tool, access the ICP PID. Is the ICP PID voltage 0.18-0.24 volts? If yes, go to next step. If no, install a new ICP sensor. - 4) Check For Input Sensor Bias
Using scan tool, access the BARO, MAF and MAP PIDs. See appropriate PIN VOLTAGE/PID VALUE CHARTS article for normal operating values. Are the BARO and MAP PIDs within specifications and is the MAP and BARO PID values within 6.9 kPa (1.0 psi) of each other? If yes, go to next step. If no, see appropriate SYSTEM TEST to continue sensor diagnostics. - 5) Check The Turbocharger Operation Boost
Key on, engine running. Using scan tool, access PCM and monitor MGP, EGR_DC, RPM and VGTDC PIDs. Access PCM and control the EGRDC, RPM_DSD and VGTDC PIDS. Increase the commanded engine speed to 1200 RPM using output state control. The calibration may limit the actual RPM between 1150 and 1200 RPM. Decrease the EGR duty cycle to 0 percent. Decrease the VGT duty cycle to 0 percent. Record the MGP PID value. Increase the VGT duty cycle to greater than 85 percent. Record the MGP PID value. Decrease VGT duty cycle to 0 percent. Record the MGP PID value. Is the MGP PID below 3 kPa (0.44 psi) at 0 percent VGT duty cycle and above 50 kPa (7.3 psi) at 85 percent duty cycle? If yes, go to next step. If no, go to step 7). - 6) Check The Turbocharger Operation Back Pressure
Key on, engine running. Using the gauge bar, access the exhaust pressure sensor port. Access the PCM and monitor the EGR_DC, RPM and VGTDC PIDs. Access PCM and control the EGRDC, RPM_DSD and VGTDC PIDs. Increase the commanded speed to 1200 RPM using output state control. The calibration may limit the actual RPM between 1150 and 1200 RPM. Decrease the EGR duty cycle to 0 percent. Decrease VGT duty cycle to 0 percent. Record the exhaust pressure. Increase the VGT duty cycle to greater than 85 percent. Record the exhaust pressure. Decrease the VGT duty cycle to 0 percent. Record the exhaust pressure. Is the exhaust pressure gauge reading below 5 kPa (0.73 psi) at 0 percent VGT duty cycle and above 50 kPa (7.3 psi) at 85 percent VGT duty cycle? If yes, go to step 8). If no, go to next step. - 7) Check The Charge Air Cooler, Air Intake And Exhaust Systems For Leaks
Key in OFF position. Disconnect the hose from the exhaust pressure sensor. Plug the exhaust pipe. Connect the smog machine to the exhaust pressure sensor hose. Fill the exhaust system with smoke. pressurize the exhaust system with 20 psi regulated air. Disconnect the hose from the MAP sensor. Inspect MAP sensor hose and manifolds for damage, leaks, restrictions and correct routing. Connect smoke machine 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 system for leaks. Are any leaks present? If yes, repair leaks as necessary. Clear the DTCs and repeat self-test. If no, go to step 9). - 8) Check The VGT Actuator Stability
Apply the parking brake. Place 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, MGP, EGR_DC and VGTDC PIDs. Access the PCM and control the EGRDC PID. Decrease the EGR duty cycle to 0 percent. Allow the IPR to stabilize. Slowly press the accelerator pedal and hold each for 5 seconds at each of the following RPMs:- 1500
- 1800
- 2000
- 2200
- 2500
- 2800
- 9) Check The Operation Of The VGT Actuator
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 VTC 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 percent. Is any internal valve cam follower movement present when the VGT duty cycle is increased? If yes, go to next step. If no, go to TEST AK: VARIABLE GEOMETRY TURBO OUTPUT . - 10) 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 VTC PID. Increase the VGT duty cycle from 20 percent to greater than 85 percent. 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? If yes, the turbocharger system is operating correctly. Clear the DTCs and repeat the self-test. If no, install a new turbocharger assembly. See TURBOCHARGER .
NOTE:
Diagnose all other DTCs before diagnosing P132B.
NOTE:
For DTC P132B, allow the engine to idle for 5 minutes at normal operating temperature. Clear the DTCs. Repeat the self-test. If the DTC P132B is retrieved again, continue diagnosis of P132B.
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.
NOTE:
Diagnose any EOT sensor DTCs before continuing with this step.
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 self-test to verify all DTCs are cleared.
NOTE:
This test may cause a misfire or rough idle condition.
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 off the valve at this time. Do not let the valve come in contact with materials that could contaminate the valve mechanism.