Removal And Installation: Turbocharger: Removal

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

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.

NOTE: Removal steps in this procedure may contain installation details.

With the vehicle in NEUTRAL, position it on a hoist, refer to Jacking and Lifting .
- Tighten to 5 Nm (44 lb-in).
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- Tighten to 5 Nm (44 lb-in).
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Remove the catalytic converter, refer to Catalytic Converter - 2.0L GTDI .
- Tighten to 5 Nm (44 lb-in).
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- Tighten to 5 Nm (44 lb-in).
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Drain the cooling system, refer to Cooling System Draining, Filling and Bleeding .
NOTE: Make sure that 2 new linked washers are installed.

NOTE: Both water outlet tube clamps must be installed between the 2 paint stripes on hoses.
- Tighten to 28 Nm (21 lb-ft).
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NOTE: Make sure that 4 new turbocharger oil supply pipe gaskets are installed.
- Tighten to 25 Nm (18 lb-ft).
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NOTE: Make sure that a new turbocharger oil supply filter is installed.

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- Tighten to 10 Nm (89 lb-in).
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NOTE: Make sure that a new turbocharger oil drain tube is installed. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

Discard the specified component. Follow local disposal regulations.
- Tighten to 10 Nm (89 lb-in).
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NOTE: Make sure that 2 new turbocharger oil drain tube gaskets are installed. By not doing so, the turbocharger oil drain tube may leak and cause engine damage.

Discard the 2 turbocharger oil return tube gaskets.

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NOTE: Make sure that 4 new turbocharger nuts are installed.

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NOTE: Make sure that a new turbocharger gasket and 4 new turbocharger-to-cylinder head studs are installed.

Remove and discard the turbocharger gasket and the 4 turbocharger-to-cylinder head studs.
- Tighten to 17 Nm (150 lb-in).

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