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.

Drain the cooling system. Refer to Engine Cooling System Draining, Vacuum Filling and Bleeding .
Remove the power transfer unit. Refer to Power Transfer Unit .
Remove the air cleaner outlet pipe. Refer to Air Cleaner Outlet Pipe .
Disconnect the turbocharger bypass valve electrical connector, then detach the harness retainer from the inlet pipe. Release the upper charge air cooler inlet pipe lower retaining clip. Loosen the inlet pipe clamp, then remove the upper charge air cooler inlet pipe.

Courtesy of FORD MOTOR COMPANY
Remove the battery tray. Refer to Battery Tray .
Remove and discard the catalytic converter nuts, then move the catalytic converter out of the way.

Courtesy of FORD MOTOR COMPANY
Remove and discard the gasket.

Courtesy of FORD MOTOR COMPANY
Remove the bolts, then remove and discard the turbocharger oil supply tube.

Courtesy of FORD MOTOR COMPANY
Remove the bolts, then remove and discard the turbocharger oil return tube.

Courtesy of FORD MOTOR COMPANY
Remove the bolt, then remove the outer half of the turbocharger coolant return tube.

Courtesy of FORD MOTOR COMPANY
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. Inspect the rubber gasket. Install new components as needed.

Material

: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

Courtesy of FORD MOTOR COMPANY
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.
Courtesy of FORD MOTOR COMPANY
Remove the bolt, then remove the outer half of the turbocharger coolant supply tube.

Courtesy of FORD MOTOR COMPANY
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
Courtesy of FORD MOTOR COMPANY
Disconnect the turbocharger electrical connector.

Courtesy of FORD MOTOR COMPANY
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.

Courtesy of FORD MOTOR COMPANY
Remove and discard the turbocharger gasket.

Courtesy of FORD MOTOR COMPANY
Remove the turbocharger mounting studs, if they need to be removed.

Courtesy of FORD MOTOR COMPANY
Remove the bolt, then remove the heat shield, if it needs to be removed.

Courtesy of FORD MOTOR COMPANY
Remove the turbocharger exhaust flange studs, if they need to be removed.

Courtesy of FORD MOTOR COMPANY
Remove the turbocharger coolant tubes, if they need to be removed. Refer to Turbocharger Coolant Return Tube . Refer to Turbocharger Coolant Supply Tube .