Removal And Installation: Turbocharger: Removal

NOTE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

NOTE: The turbocharger wastegate actuator locknuts are not adjustable. Do not attempt to adjust the wastegate actuator locknuts or engine damage may occur.

NOTE: Do not disassemble the turbocharger. Doing so may cause turbocharger or engine damage to occur.

With the vehicle in NEUTRAL, position it on a hoist. REFER to JACKING AND LIFTING for lifting points.
If equipped, remove the splash shield.
Remove the catalytic converter - 2.0L GTDI. REFER to CATALYTIC CONVERTER - 2.0L GTDI .
Remove the lower CAC inlet tube and the turbocharger inlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
Drain cooling system. REFER to GENERAL PROCEDURES - Cooling System Draining, Filling and Bleeding.
NOTE: Install new linked washers.

Remove the water outlet tube and water inlet hose assembly and discard the linked washers.
- Tighten to 28 Nm (21 lb-ft).
Fig 1: Locating Hose Mounting Bolts And Linked Washers
Courtesy of FORD MOTOR CO.
Disconnect the 2 turbocharger vacuum hose connections.

Fig 2: Identifying Vacuum Hose Connection Clips
Courtesy of FORD MOTOR CO.
NOTE: Install a new cylinder block oil to engine turbocharger pipe and 2 seal washers.

Remove and discard the cylinder block oil to engine turbocharger pipe and the 2 seal washers.
- Tighten to 25 Nm (18 lb-ft).
Fig 3: Removing Cylinder Block Oil To Engine Turbocharger Pipe And Seal Washers
Courtesy of FORD MOTOR CO.
Disconnect the 2 turbocharger electrical connectors.

Fig 4: Locating Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the 2 turbocharger vacuum hose connections.

Fig 5: Locating Vacuum Hose Heat Insulators
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the heat shield.
- Tighten to 10 Nm (89 lb-in).
Fig 6: Locating Heat Shield Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install a new turbocharger oil drain tube and gaskets. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

NOTE: Install a new turbocharger oil drain tube and gaskets.

Remove and discard the turbocharger oil drain tube and gaskets.
- Tighten to 10 Nm (89 lb-in).
Fig 7: Removing Turbocharger Oil Drain Tube
Courtesy of FORD MOTOR CO.
Remove the turbocharger and discard the 4 nuts and gasket.

Fig 8: Removing Exhaust Pipe Mounting Bolts
Courtesy of FORD MOTOR CO.