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 feed, the oil drain, and the coolant lines, 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 lines 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
Remove the cowl panel grille. Refer to: Cowl Panel Grille
Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe
Remove the charge air cooler intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe
Disconnect the turbocharger control hose. Use the General Equipment: Hose Clamp Remover/Installer

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Remove the bolts, then remove and discard turbocharger oil supply tube. Discard the designated bolt.

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Loosen the turbocharger coolant tube bolt, then disconnect the turbocharger coolant tubes and move out of the way.

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NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
1. Remove and discard the turbocharger coolant tube O-ring seals.
- Inspect the turbocharger tube and the sealing surfaces. Ensure that the retaining bracket is not bent, check for square-ness of the retaining bracket to the O-ring area. Use brake cleaner and a nylon brush to clean.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
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Remove the bolts and the nut, then remove the turbocharger heat shield.

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LHD FWD/RHD FWD
Remove the catalytic converter. Refer to: Catalytic Converter
Remove the bolts and the nut, then remove the bracket.

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LHD AWD/RHD AWD
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
All Vehicles
Remove the bolts, then remove and discard the turbocharger oil return tube.

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Remove and discard the turbocharger mounting nuts, then remove the turbocharger.

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Remove the bolt, then remove and discard the turbocharger gasket.

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Remove and discard the turbocharger mounting studs.

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Only if needed, remove the turbocharger elbow adapter nuts, then remove elbow adapter.

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Only if needed, remove the turbocharger studs.

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If the turbocharger elbow adapter was removed, then inspect, clean and replace the gasket as needed.

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