Turbocharger Disassembly

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.

Remove the turbocharger. For additional information, refer to Turbocharger removal.

NOTE: Turbocharger compressor side shown in illustration, turbocharger turbine side similar.

Inspect the turbocharger compressor and turbine fins for damage.
- If the compressor or turbine wheel fins are damaged, replace the turbocharger.
- Inspect the air intake system for foreign material or leakage that would allow unfiltered air to reach the turbocharger.
  
  Fig 1: Locating Air Intake System
  Courtesy of FORD MOTOR CO.
Check the turbocharger bearing clearance. For additional information, refer to DIAGNOSIS AND TESTING .
- If readings exceed specifications, install a new turbocharger.
Cover the inlet and outlet of the turbocharger compressor housing with duct tape or covers.
Clean the oil supply tube mounting surface and cover with duct tape or covers.
Cover or place a clean paper towel into the turbocharger oil drain passage.
Remove the 3 bolts and the turbocharger heat shield.

Fig 2: Locating Bolts And Turbocharger Heat Shield
Courtesy of FORD MOTOR CO.

NOTE: Index-mark the clamp location on the compressor housing. Do not index-mark the center housing and rotating assembly, it may have to be replaced.

Fig 3: Locating Index-Mark

Courtesy of FORD MOTOR CO.

Index-mark the location and direction of the V-band clamp to aid in assembly.
Index-mark the location of the turbine housing at the unison ring crank to aid in assembly.

Fig 4: Locating Index-Mark
Courtesy of FORD MOTOR CO.
Completely remove the V-band clamp retaining nut. Position the V-band clamp from the turbocharger flanges so that the turbocharger can be separated.

Fig 5: Locating V-Band Clamp Retaining Nut
Courtesy of FORD MOTOR CO.
Using a brass drift, separate the turbine housing from the turbocharger assembly.
- Remove the V-band clamp.
  
  Fig 6: Locating V-Band Clamp
  Courtesy of FORD MOTOR CO.

NOTE: Do not attempt to clean rust, corrosion or pitting from the center housing flange.

NOTE: Scaly rust, corrosion or pitting may be present inside the turbine housing. Do not replace the turbine housing. A turbocharger vane cleaning will be sufficient.

NOTE: If the turbocharger is coked with carbon deposits from oil, the deposits will be wet and black and cover the complete inside of the turbine housing.

Remove the turbocharger vanes and unison ring from the turbine housing. Inspect all parts of the turbocharger assembly.
- If the unison ring is obviously cracked or has excessive wear in the slots, replace the unison ring. If no damage is obvious, the unison ring will be reinspected after cleaning. Proceed to Turbocharger Cleaning .
- If corrosion is present on the bearing housing flange, replace the Center Housing Rotating Assembly (CHRA). Proceed to Center Housing Rotating Assembly (CHRA) Replacement .
- If the turbocharger is oil coked, proceed to Turbocharger Cleaning .