Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .
Loosen the turbocharger outlet clamp.

Fig 1: Loosening Turbocharger Outlet Clamp
Courtesy of FORD MOTOR CO.
Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.

Fig 2: Disconnecting Electrical Connector
Courtesy of FORD MOTOR CO.
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 Wiring Harness From Conduit
  Courtesy of FORD MOTOR CO.
Remove the bolts for the charge air cooler tube.

Fig 4: Locating CAC Tube And Oil Fill Tube Bolts
Courtesy of FORD MOTOR CO.
Remove the retaining nuts, charge air cooler tube and bracket.

Fig 5: Locating Bracket Retaining Nuts
Courtesy of FORD MOTOR CO.
Remove the turbocharger outlet clamp.

Fig 6: Removing Turbocharger Outlet Clamp
Courtesy of FORD MOTOR CO.
Loosen the pipe at the exhaust clamp and position aside.

Fig 7: Loosening Pipe At Exhaust Clamp
Courtesy of FORD MOTOR CO.
Remove the LH bolts for the turbocharger adapter pipe.

Fig 8: Removing LH Bolts For Turbocharger Adapter Pipe
Courtesy of FORD MOTOR CO.
Remove the RH bolts for the turbocharger adapter pipe.

Fig 9: Removing RH Bolts For Turbocharger Adapter Pipe
Courtesy of FORD MOTOR CO.
Remove the exhaust gas recirculation (EGR) cooler clamp.

Fig 10: Removing Exhaust Gas Recirculation (EGR) Cooler Clamp
Courtesy of FORD MOTOR CO.
Remove the turbocharger inlet clamp and turbocharger adapter pipe.

Fig 11: Removing Turbocharger Inlet Clamp
Courtesy of FORD MOTOR CO.
Disconnect the VGT actuator electrical connector and retaining clip.

Fig 12: Disconnecting VGT Actuator Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the turbocharger oil feed tube.
- Remove and discard the gasket.
- Position the oil feed tube aside.
  
  Fig 13: Removing Bolts From Turbocharger Oil Feed Tube
  Courtesy of FORD MOTOR CO.
Remove the RH turbocharger mounting bolt.

Fig 14: Removing RH Turbocharger Mounting Bolt
Courtesy of FORD MOTOR CO.
Remove the LH turbocharger mounting bolts.

Fig 15: Removing LH Turbocharger Mounting Bolts
Courtesy of FORD MOTOR CO.

CAUTION: Use care not to damage the turbocharger outlet hose when removing the turbocharger.

Position the turbocharger to remove the turbocharger drain tube. Remove the turbocharger from the vehicle.
- Remove and discard the O-ring seals.
  
  Fig 16: Discarding O-Ring Seals
  Courtesy of FORD MOTOR CO.