Air Induction Systems: Turbocharger: Removal

WARNING: This page is about a different car, 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.

Remove turbocharger intake tube. See TURBOCHARGER INTAKE TUBE . Disconnect charge air cooler inlet pipe.
Remove wiring harness cover push pins and remove cover. See Fig 1. Disconnect 2 wiring harness push pins and position wiring harness out of the way.
Disconnect turbocharger variable vane hydraulic control valve electrical connector and remove bolts for oil supply tube. See Fig 2. Remove and discard oil supply tube gasket.
Remove wiring harness retaining bolt at turbocharger and remove retainer.
Using Quick Release Coupling Disconnect Tool, remove oil supply tube. See Fig 3.
Remove marmon clamp from turbocharger inlet and outlet.
Remove rear and front turbocharger mounting bolt. See Fig 4 and Fig 5 .
Position turbocharger and remove turbocharger oil drain tube. See Fig 6. Discard oil tube "O" ring.

Fig 1: Removing & Installing Wiring Harness Cover

Courtesy of FORD MOTOR CO.

Fig 2: Removing & Installing Variable Vane Hydraulic Control Valve & Oil Supply Tube

Courtesy of FORD MOTOR CO.

Fig 3: Removing Oil Supply Tube

Courtesy of FORD MOTOR CO.

Fig 4: Removing & Installing Rear Turbocharger Mounting Bolt

Courtesy of FORD MOTOR CO.

Fig 5: Removing & Installing Front Turbocharger Mounting Bolts (Right Shown; Left Is Similar)

Courtesy of FORD MOTOR CO.

Fig 6: Removing & Installing Turbocharger Oil Drain Tube

Courtesy of FORD MOTOR CO.