Removal And Installation: Turbocharger: Removal

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The engine oil must be changed any time the turbocharger is removed from the engine. The passages in the block underneath the turbocharger are direct passages to the lubrication system. Debris and or coolant may enter the lubrication system and engine damage may occur.

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.

Drain the engine cooling system. Refer to: ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING
Remove the lower intake manifold. Refer to: Lower Intake Manifold .
Remove the turbocharger heat shield bolts and then remove the turbocharger heat shield.

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Remove the exhaust downpipe. Refer to: Exhaust Downpipe .
NOTE: Note the LH turbocharger inlet pipe clamp orientation for installation.

Remove and discard the LH turbocharger inlet pipe clamp.

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Remove and discard the turbocharger coolant return tube bolt, then disconnect the turbocharger coolant return tube from the turbocharger and position the turbocharger coolant return tube out of the way.

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NOTE: Special attention needs to be given to the sealing ports for the coolant tube, 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.

NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
1. Inspect the turbocharger tube and the 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 necessary.
2. Remove and discard the turbocharger coolant return tube O-ring seal.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
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NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.
- Remove and discard the turbocharger mounting bolts.
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NOTE: Lift the turbocharger off the locating dowels while being careful not to allow the dowels to damage the sealing surfaces of the turbocharger while positioning the turbocharger forward for removal.
- Remove the turbocharger.
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Remove and discard the turbocharger oil supply filter.

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Remove and discard the turbocharger mounting gasket.

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