Removal & Installation: Turbocharger: Removal

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2003 Ford Pickup, 2003 Ford F550 Super Duty, 2003 Ford F450 Super Duty, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: For exploded view of turbocharger, see Fig 1.

Open the hood. Remove the engine cover located near fuel filter/water separator. Disconnect the charge air cooler inlet and outlet pipes. See Figure.
Label and disconnect the intake air heater element electrical leads, Intake Air Temperature (IAT) sensor electrical connector, Manifold Absolute Temperature (MAP) sensor electrical connector and the pressure hoses. See Figure.
Loosen the compressor manifold clamps and remove the compressor manifold. Remove and discard the compressor manifold "O" ring seal. See Figure.
Loosen the exhaust outlet pipe Marmon clamp and disconnect the exhaust outlet pipe from turbocharger. See Fig 2.
On vehicles with exhaust back pressure system, disconnect the exhaust back pressure valve by sliding the retaining clip away from the exhaust back pressure valve actuator lever. See Fig 3. Detach the exhaust back pressure valve actuator rod.
On all vehicles, label and disconnect the wastegate solenoid vacuum and the pressure lines. See Fig 4. Loosen the air inlet tube clamps and remove the air inlet tube.

NOTE: The exhaust inlet marmon clamp cannot be removed with the turbocharger installed. Exhaust inlet marmon clamp is located behind turbocharger. See Fig 5.

Loosen the Marmon clamp. Remove the turbocharger retaining bolts and remove the turbocharger. See Fig 6. Remove and discard the "O" ring seals. See Fig 7.
Disconnect the exhaust back pressure solenoid electrical connector. Remove the 4 pedestal mounting bolts and remove the turbocharger pedestal. See Fig 8. Remove and discard the 2 turbocharger pedestal to engine "O" rings.