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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2541 (Fuel Charging System - Turbocharger -- F250-F550 Super Duty) >> Diagnosis And Testing >> Turbocharger >> Component Tests >> Bearing Clearance Check >> Check Axial and Radial Shaft Movement - On Vehicle

Check Axial and Radial Shaft Movement - On Vehicle

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .
  2. Remove the degas bottle module. Refer to ENGINE COOLING .
  3. Remove the Air Cleaner (ACL) and the ACL  outlet pipe. Refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Remove the auxiliary air intake from the vehicle.
    Fig 1: Locating ACL Outlet Pipe
    G06763174Courtesy of FORD MOTOR CO.
  5. Loosen the 2 bolts for the exhaust downpipe at the Oxidation Catalytic Converter (OC).
    Fig 2: Locating Exhaust Downpipe Bolts
    G06778518Courtesy of FORD MOTOR CO.
    6. NOTE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
    NOTE: Use a back-up wrench to prevent the fittings from turning.
  6. Remove the 2 turbocharger oil supply tube banjo bolts and sealing washers.
    • Discard the sealing washers.
      Fig 3: Locating Turbocharger Oil Supply Tube Banjo Bolts
      G06778101Courtesy of FORD MOTOR CO.
  7. Remove the bolt and the turbocharger oil supply tube.
    • Remove and discard the O-ring seal.
    • Plug or cap the openings as needed.
      Fig 4: Locating Turbocharger Oil Supply Tube Bolt
      G06778102Courtesy of FORD MOTOR CO.
    8. NOTE: Roll the heat shield towards the cowl, then lift it up in the front and pull the shield forward to remove it.
    Fig 5: Locating Turbocharger Heat Shield Bolts
    G06778103Courtesy of FORD MOTOR CO.
  8. Remove the 5 bolts and the turbocharger heat shield.
  9. Remove the clamp at the turbocharger and position aside the exhaust downpipe.
    • Remove and discard the turbocharger gasket.
      Fig 6: Locating Exhaust Downpipe
      G06778104Courtesy of FORD MOTOR CO.
    10. NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
  10. Remove the 2 banjo bolts and the sealing washers at the fuel cooler.
    • Discard the sealing washers.
      Fig 7: Locating Fuel Cooler Banjo Bolts
      G06778105Courtesy of FORD MOTOR CO.
  11. Remove the 3 bolts for the turbocharger actuator cooler.
    Fig 8: Locating Turbocharger Actuator Cooler Bolts
    G06778106Courtesy of FORD MOTOR CO.
  12. Remove the 2 bolts for the fuel cooler.
    Fig 9: Identifying Fuel Cooler Bolts
    G06781026Courtesy of FORD MOTOR CO.
  13. Remove the 2 stud bolts for the fuel cooler.
    Fig 10: Locating Fuel Cooler Stud Bolts
    G06781027Courtesy of FORD MOTOR CO.
  14. Remove the 2 retaining nuts for the fuel cooler.
    Fig 11: Locating Fuel Cooler Retaining Nuts
    G06781028Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts for the fuel cooling system expansion tank. Position aside the turbocharger actuator cooler, fuel cooler and coolant expansion tank.
    Fig 12: Locating Fuel Cooling System Expansion Tank Bolts
    G06781029Courtesy of FORD MOTOR CO.
  16. Remove the fuel cooler bracket.
    Fig 13: Locating Fuel Cooler Bracket
    G06778111Courtesy of FORD MOTOR CO.
  17. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
    Fig 14: Locating Turbocharger Actuator Electrical Connector And Pin-Type Retainer
    G06778112Courtesy of FORD MOTOR CO.
  18. Remove the nut and position the oil level indicator and tube aside.
    Fig 15: Locating Tube Nut
    G06778113Courtesy of FORD MOTOR CO.
    19. NOTE: Rear bolts shown in illustration, front bolts similar.
    Fig 16: Locating Front Fuel Cooler Bracket Bolts
    G06778114Courtesy of FORD MOTOR CO.
  19. Remove the 4 bolts, the front fuel cooler bracket and the turbocharger crossover tube.
    20. NOTE: The seals in the crossover tube are one-time-use seals and must be installed new every time the connection is disassembled.
    NOTE: Large remover shown in illustration, small remover similar.
    Fig 17: Removing Turbocharger Crossover Seal From Crossover Tube
    G06778115Courtesy of FORD MOTOR CO.
  20. Position the crossover tube in a soft-jawed vise. Using the Air Crossover Seal Remover/Installer and Slide Hammer, remove and discard the turbocharger crossover seal from each end of the crossover tube.
  21. Disconnect the crankcase ventilation drain tube.
    Fig 18: Locating Crankcase Ventilation Drain Tube Clamp
    G06778116Courtesy of FORD MOTOR CO.
    22. NOTE: Use one of the turbocharger crossover tube mounting holes in the LH valve cover bracket to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the Dial Indicator, then push from the other end or pull the shaft.
    Fig 19: Checking High-Pressure Turbocharger Axial End Play Using Dial Indicator Gauge With Holding Fixture
    G06778117Courtesy of FORD MOTOR CO.
  22. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure turbocharger axial end play. Compare the reading with the axial end play specification.
    23. NOTE: Use one of the turbocharger crossover tube mounting holes in the LH valve cover bracket to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The radial shaft moment check is done by pushing up and down on the turbocharger shaft. Zero the Dial Indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
    Fig 20: Checking High-Pressure Turbocharger Radial Shaft Movement Using Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
    G06778118Courtesy of FORD MOTOR CO.
  23. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the high-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement specification.
    24. NOTE: Use the valve cover stud to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the Dial Indicator, then push from the other end or pull the shaft.
    Fig 21: Checking Low-Pressure Turbocharger Axial End Play Using Dial Indicator Gauge With Holding Fixture
    G06778119Courtesy of FORD MOTOR CO.
  24. Using the Dial Indicator Gauge with Holding Fixture, check the low-pressure turbocharger axial end play. Compare the reading with the axial end play specification.
    25. NOTE: Use a turbocharger bolt to mount the Dial Indicator Gauge with Holding Fixture. Position the tip of the Dial Indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The radial shaft moment check is done by pushing up and down on the turbocharger shaft. Zero the Dial Indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
    Fig 22: Checking Low-Pressure Turbocharger Radial Shaft Movement Using Dial Indicator Gauge With Holding Fixture And Clutch Housing Gauge
    G06778120Courtesy of FORD MOTOR CO.
  25. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the low-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement specification.
  26. Connect the crankcase ventilation drain tube.
    Fig 23: Locating Crankcase Ventilation Drain Tube Clamp
    G06778116Courtesy of FORD MOTOR CO.
    27. NOTE: The seals in the crossover tube are one-time-use seals and must be installed new every time the connection is disassembled.
    NOTE: Large installer shown in illustration, small installer similar.
    Fig 24: Installing Seal In Turbocharger Crossover Tube
    G06778122Courtesy of FORD MOTOR CO.
  27. Position the crossover tube in a soft-jawed vise. Using the Air Crossover Seal Remover/Installer and Handle, install a new seal in each end of the turbocharger crossover tube.
    28. NOTE: Rear bolts shown in illustration, front bolts similar.
  28. Position the turbocharger crossover tube and the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 25: Locating Front Fuel Cooler Bracket Bolts
      G06778114Courtesy of FORD MOTOR CO.
  29. Position back the oil level indicator and tube and install the nut.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 26: Locating Tube Nut
      G06778113Courtesy of FORD MOTOR CO.
  30. Connect the turbocharger actuator electrical connector and pin-type retainer.
    Fig 27: Locating Turbocharger Actuator Electrical Connector And Pin-Type Retainer
    G06778112Courtesy of FORD MOTOR CO.
  31. Position the fuel cooler bracket.
    Fig 28: Locating Fuel Cooler Bracket
    G06778111Courtesy of FORD MOTOR CO.
  32. Position back the turbocharger actuator cooler, fuel cooler and coolant expansion tank. Install the 3 bolts for the fuel cooling system expansion tank.
    • Tighten to 9 Nm (80 lb-in).
      Fig 29: Locating Fuel Cooling System Expansion Tank Bolts
      G06781029Courtesy of FORD MOTOR CO.
  33. Install the 2 retaining nuts for the fuel cooler.
    • Tighten to 19 Nm (168 lb-in).
      Fig 30: Locating Fuel Cooler Retaining Nuts
      G06781028Courtesy of FORD MOTOR CO.
    34. NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.
  34. Install the 2 stud bolts for the fuel cooler.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 31: Locating Fuel Cooler Stud Bolts
      G06781027Courtesy of FORD MOTOR CO.
  35. Install the 2 bolts for the fuel cooler.
    • Tighten to 9 Nm (80 lb-in).
      Fig 32: Identifying Fuel Cooler Bolts
      G06781026Courtesy of FORD MOTOR CO.
    36. NOTE: Turbocharger actuator cooler removed for clarity.
  36. Position the turbocharger actuator cooler and install the 3 bolts. Tighten the bolts in the sequence shown in illustration in 2 stages.
    • Stage 1: Finger-tighten the bolts.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
      Fig 33: Identifying Turbocharger Actuator Cooler Bolts Tightening Sequence
      G06778288Courtesy of FORD MOTOR CO.
    37. NOTE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the fuel system.
    NOTE: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.
  37. Install the new sealing washers and 2 banjo bolts at the fuel cooler.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 34: Locating Fuel Cooler Banjo Bolts
      G06778105Courtesy of FORD MOTOR CO.
    38. NOTE: Install a new gasket on the turbocharger.
  38. Position back the exhaust downpipe and install the clamp.
    • Tighten to 15 Nm (133 lb-in).
      Fig 35: Locating Exhaust Downpipe
      G06778104Courtesy of FORD MOTOR CO.
  39. Position the turbocharger heat shield and install the 5 bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 36: Locating Turbocharger Heat Shield Bolts
      G06778103Courtesy of FORD MOTOR CO.
    40. NOTE: Install a new O-ring seal.
  40. Position the turbocharger oil supply tube and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 37: Locating Turbocharger Oil Supply Tube Bolt
      G06778102Courtesy of FORD MOTOR CO.
    41. NOTE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
    NOTE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
    NOTE: Use a back-up wrench to prevent the fittings from turning.
    NOTE: The back banjo bolt will require a torque adapter to be tightened properly.
  41. Install new sealing washers and the 2 turbocharger oil supply tube banjo bolts.
    • Calculate the correct torque wrench setting for the following torque. Refer to the illustration.
      Fig 38: Identifying Torque Wrench Adapter Formulas
      G00468730Courtesy of FORD MOTOR CO.
    • For Viton® sealing washers, using a torque adapter, tighten to 25 Nm (18 lb-ft).
    • For copper sealing washer, using a torque adapter, tighten to 38 Nm (28 lb-ft).
    • Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
      Fig 39: Locating Turbocharger Oil Supply Tube Banjo Bolts
      G06778101Courtesy of FORD MOTOR CO.
  42. Tighten the 2 bolts for the exhaust downpipe at the OC  .
    • Tighten to 40 Nm (30 lb-ft).
      Fig 40: Locating Exhaust Downpipe Bolts
      G06778518Courtesy of FORD MOTOR CO.
  43. Position the auxiliary air intake in the vehicle.
    Fig 41: Locating ACL Outlet Pipe
    G06763174Courtesy of FORD MOTOR CO.
  44. Install the Air Cleaner (ACL) outlet pipe and ACL  . Refer to INTAKE AIR DISTRIBUTION & FILTERING .
  45. Install the degas bottle module. Refer to ENGINE COOLING .
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