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: Removal steps in this procedure may contain installation details.

Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Remove the degas bottle. Refer to: Degas Bottle .
Remove the engine appearance cover.

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1. Disconnect the crankcase ventilation tube quick release coupling. Refer to: Quick Release Coupling .
2. Remove the TC air inlet pipe retaining nut, the ball stud and loosen the TC air inlet pipe clamp, then remove the TC inlet pipe.
  Torque: 44 lb.in (5 Nm)
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Position the vehicle on a hoist. Refer to: Jacking and Lifting - Overview .
Loosen the clamp and position aside the TC outlet pipe out of the way.
Torque: 44 lb.in (5 Nm)

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- Remove and discard the front axle shaft bearing bracket lower nut.
- Remove and discard the front axle shaft bearing bracket upper nut.
- Remove and discard the front axle shaft bearing bracket.
  Torque: Tighten the lower nut: 44 lb.in (5 Nm) Tighten the upper nut: 18 lb.ft (25 Nm) Re-tighten the lower nut: 18 lb.ft (25 Nm)
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NOTE: It may be necessary to rotate the fail-safe to remove the front lower bolt.

Remove the front axle shaft bearing bracket bolts and then position the axle shaft bearing bracket out of the way.

Torque: 35 lb.ft (48 Nm)

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Remove the catalytic converter. Refer to: Catalytic Converter .
1. Remove the TC coolant tube bracket bolts.
  Torque: 17 lb.ft (23 Nm)
2. Disconnect the TC coolant tube bolts from the TC.
  Torque: 21 lb.ft (28 Nm)
3. Release the clamps and then disconnect the TC coolant tubes.
4. Remove and discard the TC coolant tubes.
5. Remove the TC heat shield bolts and then remove the TC heat shield.
  Torque: 159 lb.in (18 Nm)
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Remove and discard the TC mounting nut.
Torque: 18 lb.ft (25 Nm)

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Remove the TC oil supply tube bolt and then position the TC oil supply tube aside.
Torque: 89 lb.in (10 Nm)

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Remove the TC oil drain tube bolts and then remove the TC oil drain tube.
Torque: 89 lb.in (10 Nm)

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- Remove and discard the TC oil drain tube gasket. Inspect and replace the TC oil return tube O-ring seal as needed.
- To install, lubricate the TC oil return tube O-ring seal with clean engine oil.
  Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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Disconnect the TC electrical connectors.

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- Remove and discard the TC mounting nuts and remove the TC.
  Torque: Stage 1: 18 lb.ft (25 Nm) Stage 2: 18 lb.ft (25 Nm)
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1. Remove and discard the TC mounting stud and the gasket.
  Torque: 177 lb.in (20 Nm)
2. Replace the TC oil supply tube assembly, then install and tighten the TC oil supply tube bolt.
  Torque: 19 lb.ft (26 Nm)
3. Lubricate the new TC oil supply tube O-ring seal with clean engine oil.
  Material: Motorcraft® SAE 5W-20 Synthetic Blend Motor Oil / XO-5W20-QSP (WSS-M2C945-A)
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Remove and discard the TC mounting studs.
Torque: 177 lb.in (20 Nm)

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