Removal And Installation: Turbocharger: Removal

NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

NOTE: Special attention needs to be given to the sealing ports for the oil supply, the oil return, and the coolant tubes, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the tubes to ensure that there are no leaks or repeat repairs.

All vehicles

Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
AWD (all-wheel drive) vehicles
Remove the power transfer unit. Refer to: Power Transfer Unit - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler . Refer to: Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil-to-Coolant Cooler .
FWD (front wheel drive) vehicles
Remove the right front wheel and tire. Refer to: Wheel and Tire .
All vehicles
Remove the upper air Cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
Disconnect the turbocharger bypass valve electrical connector, then detach the harness retainer from the stud bolt. Release the charge air cooler upper inlet pipe retaining clip. Loosen the charge air cooler upper inlet pipe clamp, then remove the charge air cooler upper inlet pipe.

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Loosen the lower air Cleaner outlet pipe clamp, then remove the lower air Cleaner outlet pipe.

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FWD (Front Wheel Drive) Vehicles
Remove the catalytic converter. Refer to: Catalytic Converter .
AWD (All-Wheel Drive) Vehicles
Remove the battery tray. Refer to: Battery Tray .
Remove and discard the catalytic converter nuts, then move the catalytic converter out of the way.

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Remove and discard the gasket.

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All Vehicles
Remove the bolts, then remove and discard the turbocharger oil supply tube.

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Remove the bolts, then remove and discard the turbocharger oil return tube.

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Remove the bolt, then remove the outer half of the turbocharger coolant return tube.

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1. Remove and discard the turbocharger coolant tube O-ring seal.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
  
  Use brake Cleaner and a nylon brush to clean. Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if needed.
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Remove the bolt, then remove the outer half of the turbocharger coolant supply tube.

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1. Remove and discard the turbocharger coolant tube O-ring seal.
2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
  
  Use brake Cleaner and a nylon brush to clean. Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining bracket is not bent, check for squareness of the O-ring area. Inspect the rubber gasket. Install new components if needed.
  
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
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Disconnect the turbocharger electrical connector.

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NOTE: The coolant tube bracket is retained by the left lower turbocharger stud and nut.

Remove the turbocharger mounting nuts, detach the coolant tube bracket, then remove the turbocharger.

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Remove and discard the turbocharger gasket.

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Remove the turbocharger mounting studs, if they need to be removed.

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Remove and discard the turbocharger exhaust flange studs.

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If needed, remove the turbocharger coolant tube bolt, then remove the turbocharger coolant return tube.

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1. NOTE: This sub-step is only needed if the component was removed.
  
  Remove and discard the turbocharger coolant tube O-ring seal.
2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
  
  NOTE: This sub-step is only needed if the component was removed.
  
  Use brake Cleaner and a nylon brush to clean. Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Inspect the rubber gasket. Install new components if needed.
  
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
3. Inspect the rubber gasket. Install new components if needed.
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If needed, remove the turbocharger coolant supply tube.

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1. NOTE: This sub-step is only needed if the component was removed.
  
  Remove and discard the turbocharger coolant tube O-ring seal.
2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
  
  NOTE: This sub-step is only needed if the component was removed.
  
  Use brake Cleaner and a nylon brush to clean. Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if needed.
  
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
3. Use brake Cleaner and a nylon brush to clean. Clean the turbocharger coolant tube gasket sealing surface. Install new components if needed.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

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