The turbo actuator is a very common problem for DIESEL MONDEOS FROM 2004.
The engine will loose all power and go into 'limp mode'. This fault normally starts out as intermittent and only happens when the engine is hot and has been running for some time, but the fault will become permanent with time.
When the unit fails you will notice the engine management light on and the coil light flashing on the instrument cluster
Common faults: ENGINE MANAGEMENT LIGHT ILLUMINATED (IN MOST CASE'S BUT NOT ALWAYS)
VEHICLE GOES INTO "LIMP MODE" WITH REDUCED POWER
TURBO / BOOST CONTROL / TURBO POSITION SENSOR fault code P132A / P132B P2263.
Things to check before having your unit rebuilt.
Ensure that you have free fluid movement of the turbo arm its self. Stop the vehicle and wait for the turbo to cool down then disconnect the c-clip from the actuator (careful the clip is very small and can have a tendency to spring off). You will now be able to manually move the turbo rod and operate the variable veins. If there is no problem with the turbo the movement should be completely free and and you should fill a hard solid stop at the end of each travel. A metallic metal on metal sound should be also be heard, This is the vanes of the turbo fully opening and shutting. If you fill and notches or restriction then your turbo may be blocked with carbon deposits. (please see image below of what this looks like internally)
If this is the case then your turbo will need cleaning in addition to the actuator being tested and rebuilt. Please note if you are getting a P0251 - Injection Pump Fuel Metering Control A Malfunction then it WILL NOT BE YOUR ACTUATOR AT FAULT UNLESS YOU ARE GETTING THE ABOVE CODES ALSO
For more information on the Electronic Turbo Actuator Reconditioning Service please see our shop.