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Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Remove the turbocharger intake tube. For additional information, refer to Turbocharger Intake Tube .
  3. Loosen the turbocharger outlet clamp.
    4. Fig 1: Locating Turbocharger Outlet Clamp
    GF0044604Courtesy of FORD MOTOR CO.
  4. Remove the bolt and position the ground wire aside. Disconnect the electrical connector pushpin.
    5. Fig 2: Identifying Ground Wire Bolt & Electrical Connector
    G03887094Courtesy of FORD MOTOR CO.
  5. Remove the conduit and position the wiring aside.
    • Disconnect the locking tab.
    • Remove the 3 bolts.
    • Disconnect the pushpin and remove the wiring harness from the conduit.
    6. Fig 3: Identifying Wire Harness Pin-Type Retainers
    G03888078Courtesy of FORD MOTOR CO.
  6. Remove the 3 bolts for the Charge Air Cooler (CAC) tube.
    7. Fig 4: Locating CAC Tube And Oil Fill Tube Bolts
    G03887097Courtesy of FORD MOTOR CO.
  7. Remove the 2 nuts, CAC tube and bracket.
    8. Fig 5: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket
    G03887099Courtesy of FORD MOTOR CO.
  8. Remove the turbocharger outlet clamp.
    9. Fig 6: Turbocharger Outlet Clamp
    GF0011978Courtesy of FORD MOTOR CO.
  9. Remove and discard the 2 nuts. Position the exhaust downpipe aside.
    10. Fig 7: Locating Nuts On Exhaust Downpipe
    GF0044559Courtesy of FORD MOTOR CO.
  10. Remove the LH 2 nuts and 2 bolts for the exhaust tube-to-exhaust manifold flange.
    • Discard the 2 nuts.
    11. Fig 8: Identifying Turbocharger Adapter Pipe Bolts
    G03887218Courtesy of FORD MOTOR CO.
  11. Remove the RH 2 nuts and 2 bolts for the exhaust tube-to-exhaust manifold flange.
    • Discard the 2 nuts.
    12. Fig 9: Identifying Turbocharger Adapter Pipe RH Bolts
    G03887224Courtesy of FORD MOTOR CO.
  12. Remove the EGR cooler clamp.
    13. Fig 10: Identifying EGR Cooler Clamp Bolt
    G03889745Courtesy of FORD MOTOR CO.
  13. Remove the turbocharger inlet clamp and turbocharger adapter pipe.
    14. Fig 11: Identifying Turbocharger Inlet Clamp
    G03888086Courtesy of FORD MOTOR CO.
  14. Disconnect the turbocharger variable vane hydraulic control valve electrical connector and remove the wiring harness from the retaining clip.
    15. Fig 12: Variable Geometry Turbocharger (VGT) Actuator Electrical Connector
    GF0011979Courtesy of FORD MOTOR CO.
  15. Remove the bolt for the turbocharger oil feed tube.
    16. Fig 13: Locating Turbocharger Oil Supply Tube Bolt
    GF0005945Courtesy of FORD MOTOR CO.
  16. Remove the 2 bolts and the turbocharger oil feed tube.
    • Remove and discard the gasket and O-ring seal.
    17. Fig 14: Turbocharger Oil Feed Tube Bolts
    GF0011980Courtesy of FORD MOTOR CO.
  17. Remove the RH turbocharger mounting bolt.
    18. Fig 15: RH Turbocharger Mounting Bolt
    GF0011981Courtesy of FORD MOTOR CO.
  18. Remove the 2 LH turbocharger mounting bolts.
    19. Fig 16: LH Turbocharger Mounting Bolt
    GF0011982Courtesy of FORD MOTOR CO.
    NOTE: Use care not to damage the turbocharger outlet hose when removing the turbocharger.
  19. Position the turbocharger to remove the turbocharger drain tube. Remove the turbocharger from the vehicle through the passenger compartment.
    • Remove and discard the O-ring seals.
    20. Fig 17: Locating Turbocharger Drain Tube
    G03888091Courtesy of FORD MOTOR CO.
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