Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different car, the 2011 Ford Pickup, 2011 Ford F550 Super Duty, 2011 Ford F450 Super Duty, and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The engine oil must be changed any time the turbocharger is removed from the engine. The passages in the block underneath the turbocharger are direct passages to the lubrication system. Debris and or coolant may enter lubrication system and engine damage may occur.

Disconnect the battery ground cable. For additional information, refer to BATTERY, BATTERY MOUNTING SYSTEM & BATTERY CABLES .
Drain the primary engine cooling system. For additional information, refer to ENGINE COOLING - DIESEL ENGINE .
Remove the lower intake manifold. For additional information, refer to ENGINE MECHANICAL - 6.7L DIESEL .
Disconnect the heater core inlet hose from the heater inlet tube.
Remove 2 bolts and the heater core inlet tube.
- Inspect O-ring seal for damage, replace if necessary.
Disconnect the turbocharger actuator electrical connector.
If equipped, disconnect the turbocharger wastegate actuator vacuum hose.
Remove the 3 bolts and turbocharger heat shield
NOTE: Mark the position of the exhaust upper downpipe clamp for installation.

Loosen the exhaust upper downpipe clamp.

Fig 1: Locating Exhaust Upper Downpipe Clamp
Courtesy of FORD MOTOR CO.
Remove the RH fender splash shield. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
Remove the exhaust upper downpipe bracket bolt.

Fig 2: Locating Exhaust Upper Downpipe Bracket Bolt
Courtesy of FORD MOTOR CO.
Remove the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts and remove the downpipe assembly.
- Discard the exhaust upper downpipe clamp.
Fig 3: Locating Exhaust Lower Downpipe-To-Catalyst And Particulate Filter Assembly Bolts
Courtesy of FORD MOTOR CO.
Loosen the RH turbocharger inlet pipe clamp and slide the clamp off the turbocharger.
- Discard the clamp after turbocharger is removed.
Loosen the LH turbocharger inlet pipe clamp and slide the clamp off the turbocharger.
- Discard the clamp after turbocharger is removed.
NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant outlet tube.

NOTE: If necessary, remove the turbocharger heat shield and discard the bolts.

Disconnect the turbocharger coolant outlet tube from the turbocharger.

Fig 4: Locating Turbocharger Coolant Outlet Tube
Courtesy of FORD MOTOR CO.
NOTE: Lift the turbocharger off locating dowels before positioning forward for removal.

NOTE: The turbocharger is a tight fit between cowl and injection pump fuel lines but comes out without removing fuel lines.

Remove the 4 bolts and the turbocharger.
- Discard the turbocharger gasket and bolts.
NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on® LDTSP4 or equivalent.

Disconnect the turbocharger coolant outlet tube at the center housing and secure tube off to the side.
- Discard the oil supply tube.
NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on® LDTSP4 or equivalent.

NOTE: Whenever the turbocharger is removed or replaced, always install a new turbocharger oil filter.

Remove and discard the turbocharger oil supply tube from the turbocharger oil supply fittings.
Remove and discard the turbocharger oil filter.

Courtesy of FORD MOTOR CO.
Inspect the turbocharger coolant outlet tube fitting at the center housing of the turbocharger and replace, as necessary.