Removal & Installation
WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cable. On vehicles with dual batteries, see DUAL BATTERIES under MISCELLANEOUS. Disconnect charge air cooler inlet and outlet pipes.
- Disconnect intake air heater element electrical leads. See Figure. Disconnect Air Charge Temperature (ACT) sensor electrical connector and Manifold Absolute Temperature (MAP) sensor electrical connector and pressure hoses.
- Loosen compressor manifold clamps and remove compressor manifold. Remove and discard compressor manifold "O" ring seal.
- Loosen exhaust outlet pipe marmon clamp at turbocharger and disconnect exhaust outlet. See Figure.
- Label and disconnect wastegate solenoid vacuum hose and pressure hose. See Fig 1. Loosen air inlet tube clamps and remove air inlet tube. On vehicles with exhaust backpressure system, disconnect backpressure valve by sliding the retaining clip toward turbocharger housing and disconnecting exhaust backpressure valve actuator rod from the exhaust backpressure valve.
- Loosen the exhaust inlet marmon clamp, remove turbocharger-to-pedestal bolts and remove turbocharger. Remove and discard turbocharger-to-pedestal "O" rings.
- To install, reverse removal procedure. Install NEW "O" rings on turbocharger pedestal and compressor manifold. Ensure marmon clamp is in positioned on exhaust inlet pipe before installing turbocharger. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .