Chapter 1 Routine maintenance and servicing

Fuel system - electronic fuel injection engines 4C•9tabs and unscrew the three retaining bolts.Disconnect the turbocharger oil and coolantpipes if required. This is as far as the unit canbe dismantled; do not disturb the wastegateor its actuator and linkage.Examination11 With the turbocharger in the vehicle,check that there are no air leaks around anypart of the air inlet components, and that theboost control valve hoses are intact andsecurely fastened.12 With the turbocharger removed, check theturbine wheels and blades (as far as possible)for signs of wear or damage. Spin the turbineand check that it rotates smoothly and easily,with no sign of roughness, free play orabnormal noise. If possible, check for axialplay (endfloat) of the shaft. Check that thewastegate, its actuator and linkage show novisible signs of wear, damage or stiffness dueto dirt and corrosion.13 If any sign of wear or damage is found,the turbocharger must be renewed.18.2 Location of turbo boost control valve(arrowed)and flexible hose connecting the turbochargerto the intercooler (see illustration 4.12). Useadhesive tape to seal the turbocharger portsagainst the entry of dirt.3 Unbolt the horn nearest the intercooler.4 Unbolt the radiator/intercooler assemblyfrom the bonnet closure panel and the bodycrossmember.5 Move the assembly as far as possibletowards the engine, and unbolt the intercoolerfrom the radiator; withdraw the intercooler.Refitting6 Refitting is the reverse of the removalprocedure, tightening all nuts and bolts to thespecified torque settings, and not forgettingto unseal the turbocharger openings beforereconnecting the intercooler pipe and hose.18 Turbocharger boost controlvalve - removal and refitting 2Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Disconnect the control valve wiring at itsmulti-plug (see illustration).3 Marking or labelling the valve hoses so thateach can be reconnected to its original union,disconnect the hoses from the valve.4 Remove the securing screws and withdrawthe valve.Refitting5 Refitting is the reverse of the removalprocedure; tighten the screws to the specifiedtorque setting.19 Turbocharger boostpressure - checking and 5adjustmentAccurate checking and adjustment of theturbocharger boost pressure requires20.4 Turbocharger/exhaust manifoldassembly detailsA Exhaust manifold-to-turbocharger boltsB Oil pipesC Coolant pipes (metal)considerable skill and experience and the useof Ford special tools and diagnostic testequipment. This work should therefore beentrusted to a Ford dealer or performanceengine specialist.20 Turbocharger - removal,examination and refitting 3Removal1 Disconnect the battery negative (earth) lead(refer to Chapter 5A, Section 1).2 Drain the cooling system as described inChapter 1.3 Remove the air inlet components asdescribed in Section 4.4 Disconnect the turbocharger coolant feedand return hoses by slackening the clampsand pulling the hoses off the turbocharger’smetal pipes (see illustration).5 Remove the pipe and flexible hosesconnecting the turbocharger to the air cleanerand intercooler. Use adhesive tape to seal theturbocharger ports against the entry of dirt.6 Disconnect the turbocharger oil feed andreturn pipes by unscrewing the couplings.7 Remove its three retaining screws andwithdraw the exhaust manifold heat shield.8 Disconnect the exhaust system downpipefrom the turbocharger, then disconnect thehose from the boost control valve to theturbocharger wastegate control actuator.9 Unscrew the exhaust manifold nuts, andwithdraw the manifold and turbocharger as anassembly, protecting the radiator withcardboard or similar.10 To separate the turbocharger from themanifold, flatten back the raised lockwasherRefitting14 Refitting is the reverse of the removalprocedure, noting the following points:a) Refit the oil and coolant pipes, tighteningthe unions to the specified torquesettings.b) Always use new lockwashers whenrefitting the turbocharger to the manifold;again, tighten the bolts to their specifiedtorque setting.c) Protect the radiator when refitting theassembly, and always fit a new exhaustmanifold gasket.d) Ensure that the oil feed and return pipesare absolutely clean before reconnectingthem and tightening them to the specifiedtorque setting.e) Owners are well advised to change theengine oil and filter whenever theturbocharger is disturbed (see Chapter1).f) When reassembly is complete and thecooling system refilled (see Chapter 1),disable the ignition system bydisconnecting the E-DIS ignition coilwiring multi-plug, then turn the engineover on the starter motor until the oilpressure light goes out. This is essentialto ensure that the turbocharger oil supplyis established BEFORE the engine isstarted; do not forget to reconnectthe coil before attempting to start theengine4C1595Ford Fiesta Remake