Mk7 Turbo boost control fault - P2563

[skweak]

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?

Glad to have found this! I'm having the same issue at 208Kms on my motorhome also. Spoken to dealership and they have said its $8.5k fix to replace the turbo charger, so im keen to investigate this idea further! Did you have to remove the TC to complete this work ??

[Maxximus]

I have. 2.4 vm dual cab chassis, have replaced egr, turbo, turbo hoses, boost sensors etc etc and still get codes p2563 and 0234. One thing, the seal on the inside of the pipe from the turbo that goes to the inter cooler keeps failing..... and the truck whistles all the way down the highway! I’m just going to live with it as the truck now has 303,000 kms

[Hossa]

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

What Jim said....we see a lot of MAF & MAP fault codes due to this issue....and people often change out their MAF & MAP sensors for new ones no reason.... and hence they still find they have the same fault codes and blame it on faulty new sensors when it's probably a duff EGR all along...a bit of a trap for young players and even some inexperienced dealers and mechanics will also fall for it.

Lord Knobrot

Really good reply…. Many thanks