Turbocharger - RH: Removal

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

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 blades are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, REFER to JACKING & LIFTING .
Drain the engine cooling system. For additional information, REFER to ENGINE COOLING .
Remove the Air Cleaner (ACL) outlet pipe, RH ACL pipe to-turbocharger pipe, RH turbocharger bypass hose and the RH turbocharger-to-Charge Air Cooler (CAC) pipe. For additional information, refer to Intake Air System Components - Exploded View, 3.5L Gasoline Turbocharged Direct Injection (GTDI) in INTAKE AIR DISTRIBUTION & FILTERING .
Remove the Air Conditioning (A/C) compressor belt. For additional information, REFER to ACCESSORY DRIVE .
Remove the 3 A/C compressor bolts and position the A/C compressor aside.

Fig 1: Locating A/C Compressor Bolts
Courtesy of FORD MOTOR CO.
Remove the exhaust Y-pipe - dual catalytic converter. For additional information, REFER to EXHAUST SYSTEM .
Rear Wheel Drive (RWD) vehicles

NOTE: The exhaust Y-pipe - dual catalytic converter procedure requires the removal of the transmission insulator and retainer and the transmission crossmember. The transmission insulator and retainer and the transmission crossmember must be installed to continue the procedure.
Install the transmission insulator and retainer and the 3 transmission insulator and retainer bolts.
- Tighten to 90 Nm (66 lb-ft).
Fig 2: Locating Transmission Insulator And Retainer Bolts
Courtesy of FORD MOTOR CO.
Install the transmission crossmember and the 4 transmission crossmember nuts and bolts (2 each side).
- Tighten to 90 Nm (66 lb-ft).
Fig 3: Locating Transmission Crossmember Nuts And Bolts
Courtesy of FORD MOTOR CO.
Lower the transmission onto the transmission crossmember and install the 2 transmission insulator and retainer nuts.
- Tighten to 103 Nm (75 lb-ft).
Fig 4: Locating Transmission Insulator And Retainer Nuts
Courtesy of FORD MOTOR CO.

Four-Wheel Drive (4WD)

NOTE: The exhaust Y-pipe - dual catalytic converter procedure requires the removal of the transmission insulator and retainer and the transmission crossmember. The transmission insulator and retainer and the transmission crossmember must be installed to continue the procedure.
Loosely install the transmission insulator and retainer and the 4 transmission insulator and retainer bolts.

Fig 5: Locating Transmission Insulator And Retainer Bolts
Courtesy of FORD MOTOR CO.
Position the transmission crossmember and loosely install the 2 transmission insulator and retainer nuts.

Fig 6: Locating Transmission Insulator And Retainer Nuts
Courtesy of FORD MOTOR CO.
Install the 4 transmission crossmember bolts and nuts.
- Tighten the transmission insulator and retainer bolts to 90 Nm (66 lb-ft).
- Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).
- Tighten the transmission insulator and retainer nuts to 103 Nm (75 lb-ft).
Fig 7: Locating Transmission Crossmember Nuts And Bolts
Courtesy of FORD MOTOR CO.

All vehicles
Remove the starter. For additional information, REFER to STARTING SYSTEM .

NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant supply tube.

NOTE: Position a drain pan prior to disconnecting the turbocharger coolant supply tube.

Using a commercially available quick disconnect tool, disconnect the turbocharger coolant supply tube at the turbocharger.
- Position the coolant supply tube aside.

NOTE: The heat insulating wrap is removed with the turbocharger bypass valve.

Disconnect the turbocharger bypass valve electrical connector. Disconnect the wastegate hose and the 2 bypass vacuum hoses.
- Remove the turbocharger bypass valve from the bracket and position aside.
Remove the 4 bolts for the turbocharger oil return tube assembly.
- Remove the 2 turbocharger center housing bolts.
- Remove the oil pressure tube bolt.
- Remove the oil drain tube bolt.
- Remove and discard the turbocharger oil return tube gasket.
Remove the turbocharger bracket bolt.

NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant return tube.

Using a commercially available quick disconnect tool, disconnect the RH turbocharger coolant return tube at the turbocharger.
Remove the 3 turbocharger mounting bolts and the turbocharger.
- Discard the turbocharger exhaust manifold gasket.
Remove the turbocharger oil return tube assembly.
- Remove and discard the turbocharger oil return tube O-ring seal.
Loosen the 2 turbocharger bracket-to-cylinder block bolts.

NOTE: Use a 3/8 inch Jiffy-tite quick disconnect tool, such as a Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant tubes.

If necessary, remove the turbocharger coolant supply and the coolant outlet tubes.
If necessary, remove the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust flange.
- Discard the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust flange gasket.
Fig 8: Locating Turbocharger Exhaust Flange Stud Bolts And Turbocharger Exhaust Flange
Courtesy of FORD MOTOR CO.