Disassembly And Assembly: Turbocharger: Disassembly

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.

Remove the turbocharger crossover tube.

Fig 1: Locating Turbocharger Crossover Tube
Courtesy of FORD MOTOR CO.

NOTE: The seals in the turbocharger 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 2: Removing Turbocharger Crossover Seal From Crossover Tube

Courtesy of FORD MOTOR CO.

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.
Remove the turbocharger tube.

Fig 3: Locating Turbocharger Tube
Courtesy of FORD MOTOR CO.

NOTE: Remove the turbocharger actuator only if the high-pressure turbocharger is being serviced.

Fig 4: Locating Turbocharger Actuator Linkage Nut

Courtesy of FORD MOTOR CO.

Remove the nut and disconnect the turbocharger actuator linkage.
Remove the 3 bolts and the turbocharger actuator.

Fig 5: Locating Turbocharger Actuator Bolts
Courtesy of FORD MOTOR CO.
Remove the turbocharger actuator insulator.

Fig 6: Locating Turbocharger Actuator Insulator
Courtesy of FORD MOTOR CO.
Measure the gap between the 2 turbochargers prior to separating them and record the gap. Using an appropriate tool, carefully separate the 2 turbochargers.

Fig 7: Locating Turbochargers Gap
Courtesy of FORD MOTOR CO.
Remove and discard the low-pressure-to-high-pressure turbocharger seal and gasket.

Fig 8: Locating Low-Pressure-To-High-Pressure Turbocharger Seal And Gasket
Courtesy of FORD MOTOR CO.

NOTE: The seal in the turbocharger is a one-time-use seal and must be installed new every time the connection is disassembled.

Fig 9: Removing Low-Pressure Turbocharger Tube Seal From Turbocharger

Courtesy of FORD MOTOR CO.

Using the Air Crossover Seal Remover/Installer and Slide Hammer, remove and discard the low-pressure turbocharger tube seal from the turbocharger.
If necessary, remove the turbocharger oil supply standoffs.
- Remove and discard the O-ring seal.
  
  Fig 10: Locating Turbocharger Oil Supply Standoffs
  Courtesy of FORD MOTOR CO.