Turbocharger - Gasoline Ford Thunderbird IX

COMPONENT TESTING

Note. Specific component testing information not available. Refer to any tests performed during REMOVAL & INSTALLATION or OVERHAUL procedures

APPLICATION

FORD MOTOR COMPANY

DESCRIPTION

The turbocharger is mounted on lower left side of 1.6L engine and on right side of 2.3L engine. It includes an electronic controlled vane air meter, turbocharger, plenum chamber, air throttle body, intake manifold, and fuel injectors. The turbocharger consists of an actuator, turbine/compressor assembly, wastegate assembly, and center housing. Turbine is spun by exhaust gas and causes compressor to draw air. Air from compressor is blown through air throttle body assembly and into intake manifold.

1.6L Turbocharged Engine Component Location. Scheme 9

2.3L Turbocharged Engine Component Location. Scheme 10

Maximum manifold pressure (boost) is controlled by an exhaust by-pass valve called a wastegate. Operation of the wastegate is controlled by a spring-loaded diaphragm called an actuator. The actuator senses intake manifold pressure to determine how much exhaust should be routed to turbine wheel. Any excess exhaust gas is by-passed around turbine wheel and into exhaust system, thus providing turbine speed limiting feature.

OPERATION

Air is drawn in through air cleaner and vane air meter. The vane air meter measures intake air flow and temperature. The compressor wheel compresses incoming air, directs it through plenum chamber, air throttle body assembly, and intake manifold.

As engine load increases and throttle is opened, more air flows into combustion chamber. Fuel is injected near the combustion chamber by an electronically-operated fuel injection nozzle (1 for each cylinder). As the air/fuel mixture is burned, greater volume of hot exhaust gas enters exhaust system. This gas is directed into turbine housing of turbocharger.

Some energy contained in exhaust gas is used to increase speed of turbine wheel. The turbine wheel is connected by a shaft to compressor wheel. As compressor wheel spins faster, it compresses incoming air and forces a denser charge into combustion chambers. Higher power output is the result.

PLENUM & AIR THROTTLE BODY

The plenum directs compressed air from compressor housing of turbocharger into air throttle body assembly. The air throttle body assembly controls amount of air entering intake manifold. A single butterfly valve, connected to conventional throttle linkage, provides air flow necessary for engine load and operating conditions. An air by-pass channel around the throttle plate controls both cold and warm engine idle air flow. The by-pass channel is regulated by an air by-pass valve which is controlled by the EEC-IV computer.

TURBINE ASSEMBLY

Turbine is mounted on left side (1.6L) and on right side (2.3L) of engine with compressor. It is connected to compressor by a shaft. When turbine wheel turns, compressor wheel must turn. Hot exhaust gas is fed into turbine through exhaust manifold. Gas hitting the turbine blades causes blades to spin. The more exhaust gas entering turbine, the faster it will spin, in turn spinning compressor faster. Thus, the turbocharger assembly can produce more power as demand increases.

WASTEGATE & ACTUATOR

When manifold pressure (boost) reaches a certain predetermined level, there must be some method of controlling or limiting boost past that point. The wastegate performs this function. Exhaust gas enters the turbine continuously. Once engine demand is satisfied and the proper boost level is attained, the wastegate, acting on command from actuator assembly, by-passes enough exhaust gas into exhaust system to maintain required turbine speed.

Actuator is a pressure-sensitive diaphragm unit. It is installed so it can sense pressure differential between intake manifold and compressor. Once this differential reaches a certain level, the diaphragm reacts on an integral spring, to partially open wastegate. The wastegate is mounted to turbine assembly.

COMPRESSOR

Compressor is connected to turbine by a shaft. As turbine wheel turns, so does compressor wheel. No exhaust gas is actually passed into compressor. The spinning compressor forces more air into intake manifold than would normally be drawn in under atmospheric pressure.

With a higher intake manifold pressure and denser charge available, more air is forced into combustion chamber on piston intake stroke. A denser mixture results in more power output from engine. The faster the compressor spins, more air is compressed into manifold. Thus, engine demand can be satisfied. (Scheme 12)

Cutaway View of 1.6L Turbocharger. Scheme 11

Exploded View of 2.3L Turbocharger Assembly. Scheme 12

OIL SUPPLY

Rotating assembly, consisting of turbine wheel, connecting shaft and compressor wheel, can reach speeds of 150,000 RPM (1.6L) and 120,000 RPM (2.3L). A sufficient supply of clean engine oil is absolutely necessary for proper operation of assembly. Engine oil enters turbocharger center housing rotating assembly through an inlet fitting. Oil drains from turbocharger through hole in bottom of center housing and is returned to engine through oil return line. Any interruption or contamination of oil will result in major turbocharger damage. An oil feed pipe runs from a fitting on left side of engine block to turbocharger. (Scheme 13)

Turbocharger Lubrication Schematic. Scheme 13

Whenever oil and filter are changed on a turbocharged engine, oil system must be primed with oil prior to starting. This can be done (after oil and filter are correctly installed) by disconnecting ignition switch electrical connector from ignition module at distributor. (Scheme 14) Crank engine several times (not longer than 30 seconds at a time) and observe when oil light goes out. Reconnect electrical connector at ignition module and start engine.

Disconnecting Ign. Sw. Electrical Connector at Distributor This connector must be disconnected and engine cranked to prime lubrication system. Scheme 14

Whenever oiling system has been contaminated in any way, change oil, filter, and flush turbocharger assembly with clean oil. Any time center housing rotating assembly is replaced, in part or in whole, oil and filter should be changed.

BOOST PRESSURE INDICATORS

Two manifold pressure switches activate a Green or Red indicator lamp mounted on the instrument panel. During normal turbocharger operation, .7-11.5 psi (.05-.81 kg/cm 2 ), the Green indicator lamp will glow.

When the boost pressure exceeds 11.5 psi (.81 kg/cm 2 ), the pressure switch will turn off the Green lamp and light the Red lamp. In addition to lighting the Red lamp, the switch will also sound a warning buzzer.

Boost Pressure Indicator System. Scheme 15

BOOST CONTROL SYSTEM (MUSTANG SVO ONLY)

The boost control system used on Mustang SVO provides electronic regulation of the wastegate actuator signal allowing up to 14 psi (.98 kg/cm 2 ) of turbo boost pressure. The system consists of a control module, solenoid/hose assembly, calibrated "T" fitting, and a relay/switch network, all controlled by the EEC-IV computer. When the system is off (fuel selector switch in Unleaded position), boost pressure is limited by normal wastegate operation.

When the system is on (fuel selector switch in Premium position), the relays signal the EEC-IV module to activate boost control strategy and connect the boost control module to the EEC-IV module. The EEC-IV module sends commands to the turbo boost control module which in turn energizes or de-energizes the solenoid. When the solenoid is energized, a portion of the pressure signal to the wastegate actuator is diverted to the inlet side of turbocharger, allowing boost pressure to increase as much as 14 psi (.98 kg/cm 2 ).

TURBOCHARGER BOOST CONTROL SYSTEM (Mustang SVO 2.3L)

1. Ensure that fuel in vehicle has an octane rating of 91 or higher. warm engine to normal operating temperature and ensure battery voltage is 11.5 volts or higher.
2. Place fuel selector switch in "PREMIUM" position. Road test vehicle at 20 MPH (1500 RPM) in 2nd gear. Quickly accelerate vehicle to 45 MPH (5500 RPM). If boost level is close to 14 psi (.98 kg/cm 2 ), go to step 3). If boost level is close to 10 psi (.7 kg/cm 2 ), go to step 4). if boost level is between 10-14 psi (.7-.98 kg/cm 2 ), go to step 6).
3. Place fuel selector switch in "UNLEADED" position. Repeat steps 1) and 2). If boost level is close to 10 psi (.7 kg/cm 2 ), system is okay. If boost level is between 10-14 psi (.7-.98 kg/cm 2 ) or close 14 psi (.98 kg/cm 2 ), go top step 8).
4. Check turbo boost control system fuse with ohmmeter. If fuse is blown, replace fuse. Only fuse (E4ZX-14A094-A) should be used. Using any other fuse may result in damage to vehicle. If okay repeat steps 1) and 2). If fuse does not blow, system is okay. If fuse blows go to step 5).
5. Replace fuse (if blown) and turbo boost module. Repeat steps 1) and 2). If system works now, system is okay. if fuse blows, go to TURBO BOOST circuit test in appropriate COMPUTERIZED ENGINE CONTROLS, FORD MOTOR CO. ELECTRONIC ENGINE CONTROL IV article. If pressure is close to 10 psi (.7 kg/cm 2 ), go to step 6).
6. Replace solenoid assembly, repeat steps 1) and 2). If system works now, system is okay. If pressure is close to 10 psi (.7 kg/cm 2 ), go to step 7).
7. Remove hoses from "T" fitting. Remove "T" fitting from turbocharger assembly and check for blockage in internal restrictor openings. If openings are clear. Install "T" fitting and hoses. Go to CIRCUIT TEST HH, TURBO BOOST in the FORD MOTOR CO. ELECTRONIC ENGINE CONTROL IV article in COMPUTERIZED ENGINE CONTROL section. If openings are plugged, clean openings, install "T" fitting and go back to step 1).
8. With engine and ignition off, place fuel selector switch in "UNLEADED" position. Disconnect solenoid hose (without Yellow stripe) form "T" fitting. Connect a hand-held vacuum pump to hose and apply 10 in. Hg of vacuum. If vacuum is held for 30 seconds without leaking, go to step 9). If not, replace turbo boost solenoid assembly and go back to step 1).
9. Repeat step 6), apply 10 in. Hg vacuum, start engine and allow it to stabilize at idle. If vacuum is held for 30 seconds without leaking, go to step 10). If not go to CIRCUIT TEST HH, TURBO BOOST in the FORD MOTOR CO. ELECTRONIC ENGINE CONTROL IV article in COMPUTERIZED ENGINE CONTROL section.
10. Place fuel selector switch in "PREMIUM" position, repeat step 6), apply 10 in. Hg vacuum, start engine and allow it to stabilize at idle. If vacuum release, go back to step 1). If vacuum is not released, go to CIRCUIT TEST HH, TURBO BOOST in the FORD MOTOR CO. ELECTRONIC ENGINE CONTROL IV article in COMPUTERIZED ENGINE CONTROL section.

Mustang SVO Turbo Boost Control System Wiring Diagram. Scheme 16

Note. Turbochargers for 1.6L & 2.3L are serviced by replacement ONLY.

1.6L

1. Manually move turbocharger shaft assembly in one direction as far as possible and spin shaft by hand.
2. Move shaft in opposite direction as far as possible and again spin shaft by hand.
3. Spin the shaft of the turbine/compressor, while moving the shaft in extreme opposite directions. If the blades DO NOT make contact with the housings, the turbocharger bearings are good.
4. If the blades DO come in contact with the housings, the bearings are worn and the turbocharger must be replaced.

2.3L

1. Remove turbocharger assembly from engine. Remove 5 bolts attaching turbine outlet elbow to center housing. Remove outlet elbow.
2. Attach a Dial Indicator Adapter (4201-C) to center housing so that indicator plunger contacts shaft. Manually push turbine wheel as far away from plunger as possible.
3. While holding turbine wheel away from plunger, set dial indicator to zero. Manually push turbine wheel assembly toward plunger as far as possible.
4. If bearing axial clearance is less than .001" (.025 mm) or greater than .003" (.076 mm), replace turbocharger assembly.

1. Remove turbocharger assembly from engine. Remove wastegate actuator rod retaining clip. Remove actuator rod from wastegate arm. Remove turbine oil inlet line from center housing.
2. Attach Dial Indicator Plunger Adapter (T79L-4201-A) to Dial Indicator (4201-C). Attach dial indicator to center housing so that plunger adapter extends through oil inlet and contacts shaft.
3. Manually apply pressure to both compressor and turbine wheels to move shaft as far away from dial indicator as possible.
4. While holding pressure on shaft, zero dial indicator. Apply pressure in opposite direction (toward dial indicator) and note dial indicator reading.
5. If bearing radial clearance is less than .003" (.076 mm) or greater than .006" (.156 mm), replace turbocharger assembly.

1.6L Only

Remove actuator diaphragm hose from inlet and attach Pressure Gauge (T79P-6634-A). Using an external source, apply 10-11 psi (.70-.77 kg/cm 2 ) to the wastegate actuator. The wastegate actuator rod should move. If not, replace turbocharger.

TURBOCHARGER ASSEMBLY

Before beginning any unit repair procedures on a turbocharging system, several general precautions should be considered.

1. Clean area around turbocharger with non-caustic solution before disassembly.
2. Use extreme care during removal to avoid damaging turbine blades. Any damage may result in turbocharger failure when engine is started.
3. Scribe reference marks on turbine and compressor housing before disassembly to ensure correct reassembly.
4. If any joints are found to be coated with sealer, clean thoroughly and recoat with sealant during assembly.

Removal 1.6L

1. Disconnect negative battery cable from battery. Remove radiator shield. Loosen and remove compressor outlet hose from turbocharger. Move hose up and out of the way.
2. Remove compressor inlet hose from the turbocharger. Remove alternator and bracket. Disconnect EGO sensor electrical connector. Raise vehicle.
3. Disconnect oil return line from bottom of turbocharger. Lower vehicle. Remove exhaust pipe from turbocharger. Disconnect heat shield from water outlet connector.
4. Disconnect oil feed line from top of turbocharger. Remove exhaust manifold-to-cylinder head nuts and move manifold far enough away to remove heat shield.
5. Remove turbocharger and exhaust manifold as an assembly. Remove 4 nuts holding turbocharger-to-exhaust manifold and remove turbocharger.

Installation

To install, reverse removal procedures. With installation complete, start engine and let idle for 30-60 seconds. Check for system leaks.

Removal 2.3L

1. Disconnect negative battery cable from battery. Remove 2 bolts retaining throttle body discharge tube to turbocharger. Loosen upper clamp on inlet hose.
2. Disconnect all vacuum hoses and tubes that may interfere with turbocharger removal. Disconnect PCV tube from turbocharger air inlet elbow. Remove throttle body discharge tube and hose as an assembly.
3. Disconnect ground wire from air inlet elbow. Remove turbocharger oil supply line. Disconnect exhaust pipe from turbocharger.
4. Raise vehicle on hoist. Remove 2 bolts that attach exhaust pipe to turbocharger. Disconnect exhaust pipe from turbocharger.
5. Remove 2 bolts from oil return line below turbocharger. Remove bolt attaching lower turbocharger bracket to engine block. Lower vehicle from hoist.
6. Remove lower front turbocharger retaining bolt. Remove 3 remaining nuts from turbocharger retaining studs. Slide turbocharger off of studs and remove from vehicle.

Reinstall turbocharger assembly in reverse order of removal procedure. Be sure to install new gaskets with bead facing outward. Tighten all bolts to specifications.

Removal

1. Disconnect hose from actuator diaphragm. Remove turbocharger from engine. Remove clip that attaches actuator rod to wastegate arm.
2. Remove 2 bolts that attach actuator diaphragm assembly to compressor housing. Remove actuator assembly.

Installation & Adjustment

1. Install 2 bolts that attach actuator diaphragm assembly to compressor housing. Tighten bolts.
2. With wastegate in fully closed position (fully forward), unscrew actuator rod end until it fits on wastegate arm pin. Install clip on arm and tighten lock nut on rod.
3. Remove horse collar from actuator rod and connect gauged low air pressure supply to actuator diaphragm. Using a dial indicator to measure actuator rod movement, slowly apply air pressure until rod moves .015" (.38 mm). Check that air pressure reads between 9.5-10.5 psi (.67-.74 kg/cm 2 ).
4. If air pressure is not within limits, readjust to correct setting, and adjust rod to .015" (.38 mm).

1. Disconnect turbocharger down pipe at outlet elbow and wastegate assembly. Remove clip that attaches actuator rod to wastegate arm.
2. Remove 5 bolts attaching outlet to center housing assembly. Remove outlet elbow from center housing.

Reinstall in reverse order of disassembly. Tighten all outlet elbow attaching bolts evenly.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS