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Home >> Ford >> 2009 >> RV Cutaway 6.0 P >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Pinpoint Tests- 6.0L Diesel Models >> Pinpoint Test KA: Turbocharger System Performance >> Test Procedure
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Test Procedure

  1. KA1 PRELIMINARY DIAGNOSIS 
    • Ignition OFF.
    • Carry out a visual inspection.
    • Ignition ON, engine OFF.
    • Record the freeze frame data.
    • Retrieve the continuous memory DTCs.
    • Carry out the KOEO and KOER self-test.

    Are any DTCs present? 

    Yes No
    For DTC P0478, GO to  KA3.
    For DTCs P0299, P2262, P2263 or P0404, GO to  KA2.
    For all others, REFER to DIAGNOSTIC TROUBLE CODE (DTC) CHARTS AND DESCRIPTIONS .    		 GO to  KA2.
  2. KA2 CHECK THE ICP SENSOR FOR BIAS 
    • Ignition ON, engine OFF.
    • Access the PCM and monitor the ICP PID.

    Is the voltage between 0.15 - 0.35 V? 

    Yes No
    GO to  KA3. INSTALL a new ICP sensor. CLEAR the DTCs. REPEAT the self-test.
  3. KA3 CARRY OUT THE EGR TEST 
    NOTE: Incorrect EGR valve operation may affect turbocharger diagnostics.
    NOTE: Refer to the scan tool information article for examples of EGR test results.
    • Using the scan tool, carry out the Powertrain Air Management Exhaust Gas Recirculation (EGR) System Test. Refer to PERFORMANCE DIAGNOSTIC PROCEDURES , Exhaust Gas Recirculation (EGR) System Test.

    Is a concern present? 

    Yes No
    REPAIR as necessary.
    CLEAR the DTCs. REPEAT the self-test.    		 GO to  KA4.
  4. KA4 CARRY OUT THE TURBO BOOST TEST 
    NOTE: If a sensor fails the turbo boost test, the test will abort. Refer to the appropriate sensor pinpoint test to continue diagnosis.
    NOTE: Refer to the scan tool information article for examples of the turbo boost test results.
    • Using the scan tool, carry out the Powertrain Air Management Turbo Boost Test.

    Are any concerns present? 

    Yes No
    For BARO sensor failure, GO to Pinpoint Test H .
    For EP sensor failure, GO to Pinpoint Test X .
    For MAF sensor failure, GO to Pinpoint Test J .
    For MAP sensor failure, GO to Pinpoint Test E .
    For all others, GO to  KA5.    		 GO to  KA5.
  5. KA5 CARRY OUT THE TURBO VVT TEST 
    NOTE: The Vane Position Sensor Cable Kit (418-626) is required to carry out this test.
    NOTE: Refer to the scan tool information article for examples of the turbo VVT test results.
    • Using the scan tool, carry out the Powertrain Air Management Turbo VVT Test.

    Are any concerns present? 

    Yes No
    GO to  KA6. GO to  KA7.
  6. KA6 CHECK THE OPERATION OF THE VGT ACTUATOR 
    NOTE: 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.
    • Ignition OFF.
    • VGT Actuator connector disconnected.
    • Remove the VGT actuator from the turbocharger assembly.
    • VGT Actuator connector connected.
    • Ignition 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 a concern present? 

    Yes No
    GO to  AK2. REMOVE the turbocharger. CHECK the turbocharger housing, vanes and unison rings for coking deposits. CLEAN as necessary. INSTALL the turbocharger and CHECK for correct operation.
    If the concern is still present, INSTALL a new turbocharger assembly. REFER to the appropriate, Fuel Charging and Controls.
  7. KA7 CHECK THE CHARGE AIR COOLER, AIR INTAKE AND EXHAUST SYSTEMS FOR LEAKS AND RESTRICTIONS 
    • Ignition OFF.
    • 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 shop 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 shop air.
    • Check air intake and exhaust systems for leaks.

    Are any leaks or restrictions present? 

    Yes No
    REPAIR the leaks or restrictions. GO to PERFORMANCE DIAGNOSTIC PROCEDURES if a driveability concern exists.
    CLEAR the DTCs. REPEAT the self-test.    		 The system is operating correctly at this time. REFER to NO DTCS PRESENT SYMPTOM CHART to diagnose the next symptom.
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