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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1608 (Engine Controls - Pinpoint Test Hf: Catalyst Efficiency Monitor And Exhaust Systems Through Pinpoint Test JC: Secondary Ignition (Coil Pack) - (Except Diesel & Hybrid)) >> Pinpoint Test HN: Turbocharger System >> Test Procedure

Test Procedure

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  1. HN1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) 
    NOTE: Diagnose circuit faults prior to range or performance faults.

    Are DTCs P0034, P0035, P00C1, P00C2, P0234, P0245, P0246 or P0299 present? 

    Yes No
    For continuous memory DTCs P0034, P0035, P00C1, P00C2, P0245 or P0246, GO to  HN2.
    For DTCs P0234 or P0299, GO to  HN2.
    For KOEO and KOER DTCs P0034 or P00C1, GO to  HN3.
    For KOEO and KOER DTCs P0035 or P00C2, GO to  HN5.
    For KOEO and KOER DTC P0245, GO to  HN7.
    For KOEO and KOER DTC P0246, GO to  HN9.    		 GO to  HN2.
  2. HN2 VISUALLY INSPECT THE TURBOCHARGER SYSTEM 
    • Visually inspect the turbocharger system for:
      • correct turbocharger wastegate control hose connection and routing
      • leaks around tubing and intake manifold
      • correct electrical connections
      • damaged or leaking exhaust system
      • turbocharger oil leaks. Refer to the appropriate Fuel Charging And Controls article & Turbocharger article .
      • damaged or restricted turbocharger oil return tubes. Refer to the appropriate Fuel Charging And Controls article & Turbocharger article .
      • damaged turbocharger. Refer to the appropriate Fuel Charging And Controls article & Turbocharger article .

    Do the visual inspections reveal any concerns? 

    Yes No
    REPAIR as necessary.
    Clear the DTCs.
    REPEAT the self-test.    		 For DTC P0234, GO to  HN16.
    For DTC P0299, GO to  HN19.
    For all other DTCs, GO to  HN13.
    For symptoms without DTCs, GO to  HN19.
  3. HN3 KOEO AND KOER DTCS P0034 AND P00C1: CHECK THE TURBOCHARGER BYPASS VALVE FOR VOLTAGE 
    • Ignition OFF.
    • Suspect TBCY Solenoid connector disconnected.
    • Ignition ON, engine OFF.
    • For DTCs P0034,
    • Measure the voltage between:
      (+) TCBY Connector, Harness Side (-)
      VPWR - Pin 1 Ground
    • For DTCs P00C1,
    • Measure the voltage between:
      (+) TCBY2 Connector, Harness Side (-)
      VPWR - Pin 1 Ground

    Is the voltage greater than 10 volts? 

    Yes No
    GO to  HN4. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  4. HN4 KOEO AND KOER DTCS P0034 AND P00C1: CHECK THE TURBOCHARGER BYPASS VALVE CONTROL CIRCUIT FOR A SHORT TO GROUND 
    • Ignition OFF.
    • PCM connector disconnected.
    • For DTCs P0034,
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-)
      TCBY - Pin E14 Ground
    • For DTCs P00C1,
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-)
      TCBY2 - Pin B4 Ground

    Is the resistance less than 10K ohms? 

    Yes No
    GO to  HN11. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  5. HN5 KOEO AND KOER DTCS P0035 AND P00C2: CHECK THE TURBOCHARGER BYPASS VALVE CONTROL CIRCUIT FOR AN OPEN 
    • For DTCs P0035,
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-) TCBY Connector, Harness Side
      TCBY - Pin E14 TCBY - Pin 2
    • For DTCs P00C2,
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-) TCBY2 Connector, Harness Side
      TCBY2 - Pin B4 TCBY2 - Pin 2

    Is the resistance greater than 10K ohms? 

    Yes No
    REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test. GO to  HN6.
  6. HN6 KOEO AND KOER DTCS P0035 AND P00C2: CHECK THE TURBOCHARGER BYPASS VALVE CONTROL CIRCUIT FOR A SHORT TO VOLTAGE 
    • Ignition OFF.
    • Suspect TBCY Solenoid connector disconnected.
    • PCM connector disconnected.
    • For DTCs P0035,
    • Measure the voltage between:
      (+) PCM Connector, Harness Side (-)
      TCBY - Pin E14 Ground
    • For DTCs P00C2,
    • Measure the voltage between:
      (+) PCM Connector, Harness Side (-)
      TCBY2 - Pin B4 Ground

    Is the voltage greater than 10 V? 

    Yes No
    REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test. GO to  HN11.
  7. HN7 KOEO AND KOER DTC P0245: CHECK THE TURBOCHARGER (TC) WASTEGATE REGULATING VALVE SOLENOID FOR VOLTAGE 
    • Ignition OFF.
    • TC Waste Gate Regulating Valve Solenoid connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
      (+) TC Waste Gate Regulating Valve Solenoid Connector, Harness Side (-)
      VPWR - Pin 2 Ground

    Is the voltage greater than 10 volts? 

    Yes No
    GO to  HN8. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  8. HN8 KOEO AND KOER DTC P0245: CHECK THE TURBOCHARGER (TC) WASTEGATE REGULATING VALVE SOLENOID CONTROL CIRCUIT FOR A SHORT TO GROUND 
    • Ignition OFF.
    • PCM connector disconnected.
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-)
      TCWRVS - Pin E16 Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to  HN12. REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test.
  9. HN9 KOEO AND KOER DTC P0246: CHECK THE TURBOCHARGER (TC) WASTEGATE REGULATING VALVE SOLENOID CONTROL CIRCUIT FOR AN OPEN 
    • Measure the resistance between:
      (+) PCM Connector, Harness Side (-) TC Waste Gate Regulating Valve Solenoid Connector, Harness Side
      TCWRVS - Pin E16 TCWRVS - Pin 1

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  HN10. REPAIR the open circuit. CLEAR the DTCs. REPEAT the self-test.
  10. HN10 KOEO AND KOER DTC P0246: CHECK THE TURBOCHARGER (TC) WASTEGATE REGULATING VALVE SOLENOID CONTROL CIRCUIT FOR A SHORT TO VOLTAGE 
    • Ignition OFF.
    • TC Waste Gate Regulating Valve Solenoid connector disconnected.
    • PCM connector disconnected.
    • Measure the voltage between:
      (+) TC Waste Gate Regulating Valve Solenoid Connector, Harness Side (-)
      TCWRVS - Pin 1 Ground

    Is any voltage present? 

    Yes No
    REPAIR the short circuit. CLEAR the DTCs. REPEAT the self-test. GO to  HN12.
  11. HN11 CHECK THE TURBOCHARGER BYPASS VALVE FOR OPEN AND SHORT CIRCUITS 
    • For turbocharger bypass (TCBY) valve:
    • Measure the resistance between:
      (+) TCBY Connector, Component Side (-) TCBY Connector, Component Side
      TCBY - Pin 2 VPWR - Pin 1
    • For turbocharger bypass 2 (TCBY2) valve:
    • Measure the resistance between:
      (+) TCBY2 Connector, Component Side (-) TCBY2 Connector, Component Side
      TCBY2 - Pin 2 VPWR - Pin 1

    Is the resistance between 9 - 10 ohms? 

    Yes No
    GO to  HN25. INSTALL a new TCBY or TCBY2.
    CLEAR the DTCs. REPEAT the self-test.
  12. HN12 CHECK THE TURBOCHARGER (TC) WASTEGATE REGULATING VALVE SOLENOID FOR OPEN AND SHORT CIRCUITS 
    • Measure the resistance between:
      (+) TC Waste Gate Regulating Valve Solenoid Connector, Component Side (-) TC Waste Gate Regulating Valve Solenoid Connector, Component Side
      TCWRVS - Pin 1 VPWR - Pin 2

    Is the resistance between 21 - 25 ohms? 

    Yes No
    GO to  HN25. INSTALL a new turbocharger (TC) wastegate regulating valve solenoid.
    CLEAR the DTCs. REPEAT the self-test.
  13. HN13 SELF-TEST DTCS P0034, P0035, P00C1, P00C2, P0245 AND P0246: INTERMITTENT CHECK 
    • Ignition ON, engine OFF.
    • For the turbocharger bypass (TCBY) valve,
    • Access the PCM and monitor the TURBO_BP1_STAT PID.
    • While observing the PID, carry out the following:
      • lightly tap on the turbocharger bypass (TCBY) valve to simulate road shock
      • wiggle the turbocharger bypass (TCBY) valve connector
    • For the turbocharger bypass 2 (TCBY2) valve,
    • Access the PCM and monitor the TURBO_BP2_STAT PID.
    • While observing the PID, carry out the following:
      • lightly tap on the turbocharger bypass 2 (TCBY2) valve to simulate road shock
      • wiggle the turbocharger bypass 2 (TCBY2) valve connector
    • For the turbocharger (TC) wastegate regulating valve solenoid,
    • Access the PCM and monitor the TWGATE_STAT PID.
    • While observing the PID, carry out the following:
      • lightly tap on the turbocharger (TC) wastegate regulating valve solenoid to simulate road shock
      • wiggle the turbocharger (TC) wastegate regulating valve solenoid connector

    Is there a change in the PID reading? 

    Yes No
    For TCBY or TCBY2, INSTALL a new TCBY or TCBY2.
    For turbocharger (TC) wastegate regulating valve solenoid, INSTALL a new turbocharger (TC) wastegate regulating valve solenoid.    		 GO to  HN14.
  14. HN14 CHECK THE ELECTRONIC ENGINE CONTROL (EEC) WIRING HARNESS 
    • For the turbocharger bypass (TCBY) valve,
    • Access the PCM and monitor the TURBO_BP1_STAT PID.
    • For the turbocharger bypass 2 (TCBY2) valve,
    • Access the PCM and monitor the TURBO_BP2_STAT PID.
    • For the turbocharger (TC) wastegate regulating valve solenoid,
    • Access the PCM and monitor the TWGATE_STAT PID.
    • While observing the PID, wiggle, shake, and bend small sections of the wiring harness while working from the valve to the PCM.

    Is there a change in the PID reading? 

    Yes No
    ISOLATE the concern. REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  HN15.
  15. HN15 CHECK THE PCM AND VEHICLE HARNESS CONNECTORS 
    • Ignition OFF.
    • PCM connector disconnected.
    • For turbocharger bypass (TCBY) valve,
    • TCBY connector disconnected.
    • For turbocharger bypass 2 (TCBY2) valve,
    • TCBY2 connector disconnected.
    • For turbocharger (TC) wastegate regulating valve solenoid,
    • TC Waste Gate Regulating Valve Solenoid connector disconnected.
    • Check for a loose connection, and damaged or corroded terminals.

    Are the connectors and terminals OK? 

    Yes No
    The concern is not present at this time.
    DISREGARD the current diagnostic trouble code (DTC) at this time. DIAGNOSE the next DTC. GO to DIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS .    		 REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.
  16. HN16 TURBOCHARGER SYSTEM PERFORMANCE OVERBOOST CONDITION 
    NOTE: Diagnose circuit faults prior to range or performance faults.
    NOTE: Visually inspect the vehicle for aftermarket accessories and performance modifications (exhaust system, turbocharger, performance chip). Refer to ENGINE CONTROL (EC) SYSTEM , Modifications to OBD Vehicles.
    • Check for aftermarket exhaust accessories and performance modifications.
    • Visually inspect the exhaust system for the following:
      • aftermarket accessories and performance modifications
      • tailpipe modifications that decrease the exhaust restriction

    Is a concern present? 

    Yes No
    REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  HN17.
  17. HN17 CHECK SUPPLY HOSE FROM HIGH PRESSURE TUBE TO TURBOCHARGER (TC) WASTEGATE REGULATING VALVE SOLENOID 
    • Check high pressure supply hose between the high pressure tube and the turbocharger (TC) wastegate regulating valve solenoid for the following:
      • disconnected or damaged hose
      • loose connections
      • blockage or obstruction

    Is a concern present? 

    Yes No
    REPAIR as necessary or INSTALL a new high pressure supply hose.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  HN18.
  18. HN18 CHECK TURBOCHARGER WASTEGATE ACTUATOR OPERATION 

    Do not exceed 103.4 kPa (15psi) of pressure applied to the turbocharger actuators, excessive pressure will damage actuators.

    NOTE: If the pressure bleeds off quickly while carrying out this test, find and repair the leak and retest the vehicle to verify that the initial concern is still present before continuing with this step.
    • Disconnect the turbocharger high pressure supply hose from the turbocharger (TC) wastegate regulating valve solenoid.
    • Using a suitable hand pump with pressure gauge, pressurize the TC wastegate regulating valve solenoid to 48.3 kPa (7 psi).
    • Ignition ON, engine OFF.
    • Access the PCM and control the TURBO_WGATE PID.
    • Command the turbocharger (TC) wastegate regulating valve solenoid duty cycle from 0% to 100%.
    • Ignition OFF.

    Did the pressure drop when the duty cycle was commanded to 100%? 

    Yes No
    GO to  HN21. INSTALL a new TC Waste Gate Regulating Valve solenoid. CLEAR the DTCs. REPEAT the self-test.
  19. HN19 TURBOCHARGER SYSTEM PERFORMANCE UNDERBOOST CONDITION 
    NOTE: For a performance concern related to a plugged or restricted exhaust, refer to GO to  HF8.
    NOTE: Diagnose circuit faults prior to range or performance faults.
    NOTE: Visually inspect the vehicle for aftermarket accessories and performance modifications (exhaust system, turbocharger, performance chip). Refer to ENGINE CONTROL (EC) SYSTEM , Modifications to OBD Vehicles.
    • Check the air filter element and housing for contamination, blockage or water intrusion.
    • Disconnect the air inlet and check for restrictions and water intrusion.
    • Check the charge air cooler (CAC) system for leaks (hoses and cooler).
    • Check the CAC and intake air system for restrictions.
    • Visually inspect the exhaust system for the following:
      • leaks, cracks, or punctures upstream of turbocharger
      • aftermarket accessories and performance modifications
      • tailpipe modifications that increase the exhaust restriction
      • plugged or restricted exhaust

    Is a concern present? 

    Yes No
    REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  HN20.
  20. HN20 CHECK THE CHARGE AIR COOLER (CAC) AND INTAKE AIR SYSTEMS FOR LEAKS AND RESTRICTIONS 
    NOTE: Remember to reinstall the IAT sensor, reconnect the CAC tube to the throttle body and remove the plastic bag from the air filter at the completion of this step.
    • Disconnect the CAC tube from the throttle body.
    • Use a suitable method to temporarily plug the CAC tube outlet.
    • Place the air filter in a plastic bag to prevent air flow out the intake port and reinstall it in the vehicle.
    • Remove the IAT sensor from the air filter housing.
    • Connect the Rotunda Smoke Machine, Fuel Evaporative Emission System Tester 218-00001 (522) or equivalent to the intake air system using the appropriate adapter for the IAT fitting.
    • Fill the intake air system with smoke.
    • Check the intake air system for leaks and restrictions.

    Are any leaks or restrictions present? 

    Yes No
    REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  HN21.
  21. HN21 CHECK THE TURBOCHARGER WASTEGATE ACTUATOR LINKAGE FOR DAMAGE OR OBSTRUCTIONS 
    • Visually inspect the suspect turbocharger wastgate actuator linkage for damage or obstructions. Repair as necessary.
    • Attempt to manually activate the suspect actuator.

    Can the suspect actuator be activated manually? 

    Yes No
    If necessary, INSTALL a new suspect turbocharger assembly.
    REFER to the appropriate Fuel Charging And Controls article & Turbocharger article .
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  HN22.
  22. HN22 CHECK TURBOCHARGER WASTEGATE ACTUATOR OPERATION 

    Do not exceed 103.4 kPa (15psi) of pressure applied to the turbocharger actuators, excessive pressure will damage actuators.

    NOTE: If the pressure bleeds off quickly while carrying out this test, find and repair the leak and retest the vehicle to verify that the initial concern is still present before continuing with this step.
    • Disconnect the turbocharger wastegate control hose from the turbocharger (TC) wastegate regulating valve solenoid.
    • Record each of the turbocharger wastgate actuator linkage positions.
    • Using a suitable hand pump with pressure gauge, pressurize the turbocharger wastegate actuator hoses to 48.3 kPa (7 psi).

    Did each turbocharger wastegate actuator linkage move from the starting position? 

    Yes No
    GO to  HN24. GO to  HN23.
  23. HN23 TURBOCHARGER WASTEGATE ACTUATOR PRESSURE TEST 

    Do not exceed 103.4 kPa (15psi) of pressure applied to the turbocharger actuators, excessive pressure will damage actuators.

    • Disconnect the control hose from the suspect actuator.
    • Using a suitable hand pump with pressure gauge, pressurize the suspect turbocharger wastegate actuator to 48.3 kPa (7 psi).

    Did the suspect turbocharger wastegate actuator linkage move from the starting position with pressure applied and return to the starting position when pressure is removed? 

    Yes No
    GO to  HN24. INSTALL a new suspect turbocharger assembly.
    CLEAR the DTCs. REPEAT the self-test.
  24. HN24 TURBOCHARGER COMPRESSOR WHEEL CHECK 
    • Inspect the turbocharger compressor wheel and housing for the following:
      • ability to spin freely
      • noise while spinning
      • damage to vanes on the compressor wheel
      • out of balance condition
      • debris in housing

    Is a concern present? 

    Yes No
    INSTALL a new suspect turbocharger assembly.
    CLEAR the DTCs. REPEAT the self-test.    		 The system is operating correctly at this time.
    RETURN to SYMPTOM CHARTS for further direction.
  25. HN25 CHECK FOR CORRECT PCM OPERATION 
    • Disconnect all the PCM connectors.
    • Visually inspect for:
      • pushed out pins
      • corrosion
    • Connect all the PCM connectors and make sure they seat correctly.
    • Carry out the PCM self-test and verify the concern is still present.

    Is the concern still present? 

    Yes No
    INSTALL a new PCM.
    REFER to FLASH ELECTRICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM) .    		 The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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