Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Remove the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .
Disconnect the charge air cooler inlet pipe.

Fig 1: Disconnecting Charge Air Cooler Inlet Pipe
Courtesy of FORD MOTOR CO.
Remove the push pins.

Fig 2: Removing Push Pins
Courtesy of FORD MOTOR CO.
Disconnect the two wiring harness push pins and position aside.

Fig 3: Disconnecting Wiring Harness Push Pins
Courtesy of FORD MOTOR CO.
Disconnect the turbocharger variable vane hydraulic control valve electrical connector.

Fig 4: Locating Turbocharger & Variable Vane Hydraulic Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolts for the oil supply tube.
- Remove and discard the gasket.
  
  Fig 5: Removing Bolts For Oil Supply Tube
  Courtesy of FORD MOTOR CO.
Remove the bolt and turbocharger oil supply tube.
- Remove and discard the O-ring.
  
  Fig 6: Removing Bolt And Turbocharger Oil Supply Tube
  Courtesy of FORD MOTOR CO.
Remove the bolt and the wire retainer.

Fig 7: Removing Bolt And Wire Retainer
Courtesy of FORD MOTOR CO.
Remove the marmon clamp from the turbocharger outlet.

Fig 8: Removing Marmon Clamp From Turbocharger Outlet
Courtesy of FORD MOTOR CO.
Remove the marmon clamp from the turbocharger inlet.

Fig 9: Removing Marmon Clamp From Turbocharger Inlet
Courtesy of FORD MOTOR CO.
Loosen the exhaust inlet pipe-to-EGR cooler clamp.

Fig 10: Locating Y-Pipe-To-EGR Cooler Clamp
Courtesy of FORD MOTOR CO.
Loosen the LH exhaust inlet pipe-to-exhaust manifold nuts.

Fig 11: Locating LH Exhaust Inlet Pipe-To Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Loosen the RH exhaust inlet pipe-to-exhaust manifold nuts.

Fig 12: Locating RH Exhaust Inlet Pipe-To Exhaust Manifold Nuts
Courtesy of FORD MOTOR CO.
Remove the rear turbocharger mounting bolt.

Fig 13: Removing Rear Turbocharger Mounting Bolt
Courtesy of FORD MOTOR CO.

NOTE: Left side shown, right side similar.

Fig 14: Removing Front Mounting Bolts

Courtesy of FORD MOTOR CO.

Remove the front mounting bolts.
Position the turbocharger and remove the turbocharger drain tube.
- Remove and discard the drain tube O-rings.
  
  Fig 15: Removing Turbocharger Drain Tube
  Courtesy of FORD MOTOR CO.
Remove the turbocharger.