Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different variant/trim than selected.

1.

With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .

2.

Position the hose aside, remove the oil filler cap and remove the engine appearance cover. Reinstall the oil filler cap.

Courtesy of FORD MOTOR COMPANY

3.

Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .

4.

Disconnect and position aside the hose from the ACL (air cleaner) housing.

Courtesy of FORD MOTOR COMPANY

5.

Detach the power steering reservoir and position aside.

Courtesy of FORD MOTOR COMPANY

6.

NOTE: Do not use silicone based sprays or lubricants on any components installed onto or around the diesel exhaust system or intake air distribution and filtering system. Silicone reacts with the Nitrogen Oxides (NOx) sensors and may cause permanent damage to the NOx sensors.

NOTE: The catalytic converter works like a catalytic converter/DPF. The fuel vaporizer system glow plug adds diesel fuel to the catalytic converter/ DPF which helps clean the exhaust system emissions.

NOTE: If the catalytic converter is not being replaced, the 2 exhaust gas temperature sensors and the 2 NOX sensors do not need to be removed from the catalytic converter. Disconnecting the electrical connectors is still necessary.

NOTE: Clean all exhaust connections before reassembly.

Disconnect the exhaust gas temperature sensor wiring connector and wiring retainer.

Courtesy of FORD MOTOR COMPANY

7.

Disconnect the 2 hoses to the catalytic converter/DPF.

Courtesy of FORD MOTOR COMPANY

8.

Remove the fuel vaporizer system glow plug, Refer to: Fuel Vaporizer System Glow Plug .

9.

Remove and discard the catalytic converter nuts to the TC.

Courtesy of FORD MOTOR COMPANY

10.

NOTE: Typical application shown in illustration.

Disconnect the NOX sensor electrical connector and wiring retainers.

Courtesy of FORD MOTOR COMPANY

11.

Disconnect the exhaust gas temperature sensor wiring connector.

Courtesy of FORD MOTOR COMPANY

12.

Remove the catalytic converter/DPF to DPF fasteners.

Courtesy of FORD MOTOR COMPANY

13.

Remove the heat shield and discard the gasket.

Courtesy of FORD MOTOR COMPANY

14.

Remove the catalytic converter/DPF to bracket bolts.

Courtesy of FORD MOTOR COMPANY

15.

NOTE: The catalytic converter/DPF engine bracket bolts are 2 different sizes. Note the position for installation.

Remove the catalytic converter/DPF engine bracket bolts and position the catalytic converter/ DPF back out of the way.

Courtesy of FORD MOTOR COMPANY

16.

NOTE: Note the position of the gasket for installation.

Remove and discard the gasket.

Courtesy of FORD MOTOR COMPANY

17.

If needed, remove the turbocharger exhaust studs.

Courtesy of FORD MOTOR COMPANY

18.

Disconnect the turbocharger outlet tube at the turbocharger and position aside.

Courtesy of FORD MOTOR COMPANY

19.

Remove the turbocharger oil drain tube bracket bolt.

Courtesy of FORD MOTOR COMPANY

20.

Remove and discard the engine mount nut.

Courtesy of FORD MOTOR COMPANY

21.

Position the stand on the RH back corner of the cylinder block. Position a wooden block between the oil pan and the crossmember for added safety.
Use the General Equipment: Vehicle/Axle Stands

Use the General Equipment: Wooden Block

Courtesy of FORD MOTOR COMPANY

22.

Remove the bolts and the bracket.

Courtesy of FORD MOTOR COMPANY

23.

Remove the turbocharger oil drain tube bolts and remove the turbocharger oil drain tube.

Courtesy of FORD MOTOR COMPANY

24.

Remove and discard the turbocharger oil drain tube gasket. Replace the turbocharger oil drain tube O-ring seal as necessary.

Courtesy of FORD MOTOR COMPANY

25.

Install the bracket and the bolts.

Courtesy of FORD MOTOR COMPANY

26.

Remove the stand.
Use the General Equipment: Vehicle/Axle Stands

Courtesy of FORD MOTOR COMPANY

27.

Remove the lower turbocharger mounting nuts and discard the lower turbocharger mounting nuts.

Courtesy of FORD MOTOR COMPANY

28.

Disconnect the turbocharger electrical connector.

Courtesy of FORD MOTOR COMPANY

29.

Remove the lower turbocharger heat shield bolt.

Courtesy of FORD MOTOR COMPANY

30.

Remove the upper turbocharger heat shield bolts and the turbocharger heat shield.

Courtesy of FORD MOTOR COMPANY

31.

Remove the turbocharger oil feed tube assembly and discard the turbocharger oil feed tube assembly.

Courtesy of FORD MOTOR COMPANY

32.

Remove the upper turbocharger retaining nut and the turbocharger assembly. Discard the upper turbocharger retaining nut.

Courtesy of FORD MOTOR COMPANY