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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) >> Removal And Installation >> Turbocharger - Body Off >> Removal

Turbocharger - Body Off: Removal

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.
NOTE: It is recommended that this component be serviced with the vehicle body removed. Refer to BODY -- 6.4L DIESEL . If the body cannot be removed, refer to the TURBOCHARGER - BODY ON  version of the procedure.
  1. Remove the body. For additional information, refer to FULL FRAME AND BODY MOUNTING -- F250-F550 SUPER DUTY PICKUPS .
  2. Remove the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off procedure. For additional information, refer to EXHAUST SYSTEM .
  3. Remove the clamp and disconnect the Air Cleaner (ACL) outlet tube-to-crankcase vent oil separator hose at the vent oil separator.
  4. Loosen the clamp and remove the ACL  outlet tube.
    5. 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.
  5. Remove the 2 turbocharger oil supply tube banjo bolts and sealing washers.
    • Discard the sealing washers.
  6. Remove the bolt and the turbocharger oil supply tube.
    • Remove and discard the O-ring seal.
  7. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
  8. Remove the 4 bolts for the turbocharger crossover tube and the front fuel cooler bracket.
  9. Remove the 5 bolts and the turbocharger heat shield.
  10. Remove the 2 bolts and hold downs for the turbocharger.
  11. Install the Turbocharger Lifting Bracket and 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 1: Installing Turbocharger Lifting Bracket
      G06778148Courtesy of FORD MOTOR CO.
    12. NOTE: Failure to use the Turbocharger Lifting Bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure.
    NOTE: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.
    NOTE: Use care when removing the turbocharger. The crossover tube should not be removed. The seals in the crossover tube are one-time-use seals and must be installed new.
  12. Using the Heavy Duty Floor Crane, remove the turbocharger assembly.
  13. Remove the turbocharger oil drain tubes.
    • Remove and discard the low-pressure drain tube.
    • Remove the high-pressure oil drain tube.
    • Remove and discard the 2 O-ring seals.
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