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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 On >> Removal

Turbocharger - Body On: 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: Position a suitable material in front of the Charge Air Cooler (CAC) or damage to the CAC  may occur.
NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to the TURBOCHARGER - BODY OFF  version of the procedure.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  3. Remove the Air Cleaner (ACL) assembly and ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  4. Remove the auxiliary air intake hose.
    Fig 1: Locating ACL Outlet Pipe
    G06763174Courtesy of FORD MOTOR CO.
    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.
      Fig 2: Locating Turbocharger Oil Supply Tube Banjo Bolts
      G06778101Courtesy of FORD MOTOR CO.
  6. Remove the bolt and the turbocharger oil supply tube.
    • Remove and discard the O-ring seal.
    • Plug or cap the openings as needed.
      Fig 3: Locating Turbocharger Oil Supply Tube Bolt
      G06778102Courtesy of FORD MOTOR CO.
    7. NOTE: Roll the heat shield towards the cowl, then lift up in the front and remove forward.
    Fig 4: Locating Turbocharger Heat Shield Bolts
    G06778103Courtesy of FORD MOTOR CO.
  7. Remove the 5 bolts and the turbocharger heat shield.
    8. 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.
  8. Remove the 2 banjo bolts and the sealing washers at the fuel cooler.
    • Discard the sealing washers.
      Fig 5: Locating Fuel Cooler Banjo Bolts
      G06778105Courtesy of FORD MOTOR CO.
  9. Remove the 3 bolts for the fuel cooling system expansion tank.
    Fig 6: Locating Fuel Cooling System Expansion Tank Bolts
    G06781029Courtesy of FORD MOTOR CO.
  10. Remove the 2 bolts for the fuel cooler.
    Fig 7: Identifying Fuel Cooler Bolts
    G06781026Courtesy of FORD MOTOR CO.
  11. Remove the 2 stud bolts for the fuel cooler.
    Fig 8: Locating Fuel Cooler Stud Bolts
    G06781027Courtesy of FORD MOTOR CO.
  12. Remove the 2 nuts for the fuel cooler.
    Fig 9: Locating Fuel Cooler Retaining Nuts
    G06781028Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts for the turbocharger actuator cooler. Position the fuel cooler, fuel cooling system expansion tank and turbocharger actuator cooler aside.
    Fig 10: Locating Turbocharger Actuator Cooler Bolts
    G06778106Courtesy of FORD MOTOR CO.
  14. Remove the fuel cooler bracket.
    Fig 11: Locating Fuel Cooler Bracket
    G06778111Courtesy of FORD MOTOR CO.
  15. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
    Fig 12: Locating Turbocharger Actuator Electrical Connector And Pin-Type Retainer
    G06778112Courtesy of FORD MOTOR CO.
    16. NOTE: Engine removed from art for clarity.
  16. Remove the 2 RH turbocharger inlet pipe-to-EGR-Oxidation Catalytic Converter (OC) pipe bolts and the 2 EGR-OC  -to-turbocharger bracket bolts.
    • Discard the bolts.
      Fig 13: Locating RH Turbocharger Inlet Pipe-To-EGR-Oxidation Catalytic Converter (OC) Pipe Bolts And EGR-OC-To-Turbocharger Bracket Bolts
      G06763082Courtesy of FORD MOTOR CO.
  17. Remove the RH splash shield. For additional information, refer to FRONT END BODY PANELS .
  18. Remove the Exhaust Gas Recirculation Temperature (EGRT) sensor from the RH turbocharger inlet pipe.
    Fig 14: Locating Exhaust Gas Recirculation Temperature Sensor
    G06778167Courtesy of FORD MOTOR CO.
    19. NOTE: Index-mark the drive shaft prior to disconnecting from the axle.
    Fig 15: Locating Front Drive Shaft Bolts And Straps
    G06778168Courtesy of FORD MOTOR CO.
  19. If equipped, remove the 4 bolts, 2 straps and position aside the front drive shaft.
  20. Disconnect the Exhaust Pressure (EP) sensor tube from the EGR-OC  pipe.
    Fig 16: Locating Exhaust Pressure Sensor Tube
    G06763073Courtesy of FORD MOTOR CO.
  21. Remove the EP  sensor tube fitting from the EGR-OC  pipe.
    Fig 17: Locating EP Sensor Tube Fitting
    G06778170Courtesy of FORD MOTOR CO.
  22. Remove the EGR-OC  pipe bracket-to-bracket bolt and washer. Remove the cylinder head bracket-to-cylinder head bolt, washers and the bracket.
    • Discard the bolts.
      Fig 18: Locating EGR-OC Pipe Bracket-To-Bracket Bolt, Washer And Cylinder Head Bracket-To-Cylinder Head Bolt
      G06763074Courtesy of FORD MOTOR CO.
  23. Remove the 2 EGR-OC  -to-EGR cooler bolts.
    • Discard the bolts and gasket.
      Fig 19: Locating EGR-OC-To-EGR Cooler Bolts
      G06778172Courtesy of FORD MOTOR CO.
  24. Loosen the 2 exhaust downpipe-to-OC  pipe bolts.
    Fig 20: Locating Exhaust Downpipe Bolts
    G06778518Courtesy of FORD MOTOR CO.
    25. NOTE: LH shown in illustration, RH similar.
    Fig 21: Locating LH And RH Turbocharger Inlet Pipes-To-Exhaust Manifold Nuts
    G06763096Courtesy of FORD MOTOR CO.
  25. Remove and discard the 6 LH and RH turbocharger inlet pipes-to-exhaust manifold nuts.
  26. Remove and discard the exhaust downpipe clamp. Position aside the exhaust downpipe.
    • Remove and discard the exhaust downpipe gasket.
      Fig 22: Locating Exhaust Downpipe
      G06778104Courtesy of FORD MOTOR CO.
  27. Remove the 6 turbocharger inlet pipe bolts and EGR-OC  -to-turbocharger bracket.
    • Discard the bolts and gaskets.
      Fig 23: Locating Turbocharger Inlet Pipe Bolts
      G06763078Courtesy of FORD MOTOR CO.
  28. Remove the 3 LH turbocharger inlet pipes-to-exhaust manifold studs and gasket. Remove the LH turbocharger inlet pipe.
    • Discard the studs and gasket.
      Fig 24: Locating LH Turbocharger Inlet Pipes-To-Exhaust Manifold Studs
      G06763095Courtesy of FORD MOTOR CO.
  29. Remove the 2 outer RH turbocharger inlet pipes-to-exhaust manifold studs.
    • Discard the studs.
      Fig 25: Locating Outer RH Turbocharger Inlet Pipes-To-Exhaust Manifold Studs
      G06778178Courtesy of FORD MOTOR CO.
  30. Loosen the clamps and remove the Charge Air Cooler (CAC) tube flex coupling.
    Fig 26: Locating Charge Air Cooler Tube Flex Coupling Clamps
    G06778179Courtesy of FORD MOTOR CO.
    31. 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.
  31. Remove the fuel filter module cover, fuel filter and, using a suitable suction device, remove the fuel from the fuel filter module.
    • Cover the fuel filter housing with a covering to prevent foreign material from entering the fuel system.
      Fig 27: Locating Fuel Filter Module Cover
      G06778180Courtesy of FORD MOTOR CO.
    32. 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.
  32. Remove the banjo bolt, sealing washers and fuel cooler to fuel filter module tube.
    • Discard the sealing washers.
      Fig 28: Locating Fuel Filter Module Tube Banjo Bolt
      G06778181Courtesy of FORD MOTOR CO.
  33. Remove the nut and position the oil level indicator and tube aside.
    Fig 29: Locating Tube Nut
    G06778113Courtesy of FORD MOTOR CO.
    34. NOTE: Rear bolts shown in illustration, front bolts similar.
  34. Remove the 4 bolts for the turbocharger crossover tube.
    • Remove the front fuel cooler bracket.
      Fig 30: Locating Front Fuel Cooler Bracket Bolts
      G06778114Courtesy of FORD MOTOR CO.
  35. Remove the bolt for the engine wiring harness.
    Fig 31: Locating Engine Wiring Harness Bolt
    G06778184Courtesy of FORD MOTOR CO.
    36. 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.
    NOTE: Use a commercially available disconnect tool and a screwdriver to release the fuel tube.
    Fig 32: Locating Fuel Injection Pump Supply Tubes
    G06778185Courtesy of FORD MOTOR CO.
  36. Disconnect the fuel injection pump supply tube at the fuel filter module.
  37. Remove and discard the oil filter element and O-ring seal.
    Fig 33: Identifying Oil Filter Element O-Ring Seal
    G06778186Courtesy of FORD MOTOR CO.
  38. Remove the 4 Torx bolts and the oil filter housing.
    Fig 34: Locating Oil Filter Housing Torx Bolts
    G06778187Courtesy of FORD MOTOR CO.
  39. Remove the screw and the oil filter return tube assembly.
    Fig 35: Locating Oil Filter Return Tube Assembly Screw
    G06778188Courtesy of FORD MOTOR CO.
  40. Remove and discard the oil filter base gasket and seal.
    • Cover the oil cooler to prevent foreign material from entering.
      Fig 36: Locating Oil Filter Base Gasket And Seal
      G06778189Courtesy of FORD MOTOR CO.
  41. Disconnect the EGR valve electrical connector.
    Fig 37: Locating EGR Valve Electrical Connector
    G06778190Courtesy of FORD MOTOR CO.
  42. Remove the 2 bolts and the hold downs for the turbocharger.
  43. Install the Turbocharger Lifting Bracket and 2 bolts.
    • Tighten to 20 Nm (177 lb-in).
      Fig 38: Installing Turbocharger Lifting Bracket
      G06778149Courtesy of FORD MOTOR CO.
    44. 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.
  44. With the help of an assistant, using the Heavy Duty Floor Crane, remove the turbocharger assembly.
    • Remove and discard the RH turbocharger inlet pipe gasket at the RH exhaust manifold.
  45. 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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