rossco_pb wrote:Had a dreaded power train fault light appear and van went into limp mode. Pulled over, stop and start and all good until floored it on a hill and faulted again so dropped into nearest Ford and $98 later told is P2563 which is Turbo boost control position sensor circuit. They cleared code - pcm all up to date and no other problems. Was advised that it can be an issue with this model vehicle (2008, LWB, 140ps engine) but it should be ok for maybe a year or so if lucky. Ford approach to repair is to replace whole turbo assy. Van has only done about 62k km (motorhome).
After code cleared I was not able fault again so I asked Ford had they tweaked something - they say no, just read and cleared code. Strange...
So, did some research on net and found crowds that refurbish the Garrett control unit but all in the UK - but me in NZ so took it apart to see what gives and found worm drive gear assy grubby due to wear of the worm (no lubrication) and lots of end float which is turn translates into actuator arm freeplay. Removed the motor and gear assy and shimmed it to remove end play and lubricated with silicon grease and reassembled and reinstalled and still cannot make it fail. Actuator arm into turbo very free so does not feel like the vanes sticking...
Installed a boost gauge I had sitting around so I can see what is happening and find that there is always boost present unless decelerating - peaks at about 19lb and then pcm drops it back to the max of 17lb so no apparent problems there.
What I don't understand is the Ford take on the issue, ie that sometimes these glitches occur and at some point in the future it will fail... Does anyone have any insight as to what it may be that is causing this type of issue with this particular model of transit (and Garrett actuator) as from what Ford said it is quite common?
yes correct, none at idle either. Makes you wonder when it ever thinks it can open the EGR as presumably it would not open if boost pressure present?There should be no boost at all at idle though
rossco_pb wrote:Cheers for that - perhaps I will install a fan to blow on the actuatoryes correct, none at idle either. Makes you wonder when it ever thinks it can open the EGR as presumably it would not open if boost pressure present?There should be no boost at all at idle though
Is handy having the boost gauge on, can see what is happening:-)
Jim Archer wrote:EGR operates any time the manifold vacuum is expected to drop below that of the exhaust manifold where the EGR feed is taken.
Hence why they can show a MAP or MAF code when the EGR valve sticks as inlet pressure and/or flow isn't what the ECM expects to see - thus it assumes something is wrong .... somewhere ....
Jim
rossco_pb wrote:I am wondering if the sensor intermittent failure may be due to thermal fatigue of the solder on the control board. Same sort of thing happens to graphics chips in computers - in those situations you can sometimes repair by cooking the board in an over to re-flow the solder joints. Unfortunately this is not practical with the Garrett board as the board is not easily removed plus is is completely or partially lacquered...
Given this thing is likely to fail again I have installed a fan above it (and the turbo) so as to try and keep it a bit cooler. I was thinking of also adding a layer of insulating material between the alloy case and the bracket that is bolted to the turbo but a bit worried about mucking up alignment of the actuator arm. Will see how it goes with a fan running on it... held in place with cable ties, really professional lol
knobby1 wrote:I dunno how well that will work since the air it's blowing will tend to be hot as well
Lord Knobrot
Jim Archer wrote:Time to leap out and check if the vane control arm is still free moving.
Jim
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