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Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, and 2004 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 & LIFTING .
  2. Remove the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .
  3. Loosen the turbocharger outlet clamp.
    Fig 1: Loosening Turbocharger Outlet Clamp
    G02765184Courtesy of FORD MOTOR CO.
  4. Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.
    Fig 2: Disconnecting Ground Wire And Electrical Connector
    G02765185Courtesy of FORD MOTOR CO.
  5. Remove the conduit and position the wiring aside.
    • Disconnect the locking tab.
    • Remove the bolts.
    • Disconnect the push pin and remove the wiring harness from the conduit.
    Fig 3: Removing Conduit
    G02765186Courtesy of FORD MOTOR CO.
  6. Remove the bolts for the charge air cooler tube.
    Fig 4: Removing Charge Air Cooler Tube Bolts
    G02765187Courtesy of FORD MOTOR CO.
  7. Remove the retaining nuts, charge air cooler tube and bracket.
    Fig 5: Removing Charge Air Cooler Tube And Bracket
    G02765188Courtesy of FORD MOTOR CO.
  8. Remove the turbocharger outlet clamp.
    Fig 6: Removing Turbocharger Outlet Clamp
    G02765189Courtesy of FORD MOTOR CO.
  9. Loosen the pipe at the exhaust clamp and position aside.
    Fig 7: Removing Turbocharger Exhaust Clamp Bolts
    G02765190Courtesy of FORD MOTOR CO.
  10. Remove the LH bolts for the turbocharger adapter pipe.
    Fig 8: Removing Turbocharger Adapter Pipe LH Bolts
    G02765191Courtesy of FORD MOTOR CO.
  11. Remove the RH bolts for the turbocharger adapter pipe.
    Fig 9: Removing Turbocharger Adapter Pipe RH Bolts
    G02765192Courtesy of FORD MOTOR CO.
  12. Remove the exhaust gas recirculation (EGR) cooler clamp.
    Fig 10: Removing Exhaust Gas Recirculation (EGR) Cooler Clamp
    G02765193Courtesy of FORD MOTOR CO.
  13. Remove the turbocharger inlet clamp and turbocharger adapter pipe.
    Fig 11: Removing Turbocharger Inlet Clamp And Turbocharger Adapter Pipe
    G02765194Courtesy of FORD MOTOR CO.
  14. Disconnect the VGT actuator electrical connector and retaining clip.
    Fig 12: Disconnecting VGT Actuator Electrical Connector And Retaining Clip
    G02765195Courtesy of FORD MOTOR CO.
  15. Remove the bolts from the turbocharger oil feed tube.
    • Remove and discard the gasket.
    Fig 13: Removing Bolts From Turbocharger Oil Feed Tube
    G02765196Courtesy of FORD MOTOR CO.
  16. Remove the RH turbocharger mounting bolts.
    Fig 14: Removing RH Turbocharger Mounting Bolts
    G02765197Courtesy of FORD MOTOR CO.
  17. Remove the LH turbocharger mounting bolts.
    Fig 15: Removing LH Turbocharger Mounting Bolts
    G02765198Courtesy of FORD MOTOR CO.
    18. CAUTION: Use care not to damage the turbocharger outlet hose when removing the turbocharger.
    Fig 16: Removing Turbocharger
    G02765199Courtesy of FORD MOTOR CO.
  18. Position the turbocharger to remove the turbocharger drain tube. Remove the turbocharger from the vehicle.
    • Remove and discard the O-ring seals.
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