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Home >> Mercedes Benz >> 2025 >> eSprinter Base, _NA_ >> Repair and Diagnosis >> External Pages >> Different car >> Section 2399 (Fuel Charging System 6.4L 99R Diesel Engine - Turbocharger -- F250-F550 Super Duty) >> Diagnostic Tests >> Turbocharger >> Component Tests >> Check Axial and Radial Shaft Movement - On Vehicle

Check Axial and Radial Shaft Movement - On Vehicle

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Remove the degas bottle module. For additional information, refer to ENGINE COOLING article.
  3. Remove the air cleaner and the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  4. Remove the auxiliary air intake from the vehicle.
    5. Fig 1: Locating Auxiliary Air Intake From Cowl
    GF0048542Courtesy of FORD MOTOR CO.
  5. Loosen the bolts for the exhaust downpipe at the oxidation catalytic converter (OC).
    6. Fig 2: Locating Exhaust Downpipe-To-Oxidation Catalytic Converter (OC) Pipe Bolts
    GF0048543Courtesy of FORD MOTOR CO.
    CAUTION: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
    NOTE: Use a back-up wrench to prevent the fittings from turning.
  6. Remove the turbocharger oil supply tube banjo bolts and copper sealing washers.
    • Discard the copper sealing washers.
    7. Fig 3: Locating Turbocharger Oil Supply Tube Banjo Fitting Bolts & Copper Sealing Washers
    GF0048668Courtesy of FORD MOTOR CO.
  7. Remove the bolt and the turbocharger oil supply tube.
    • Remove and discard the O-ring seal.
    • Plug or cap the openings as needed.
    8. Fig 4: Locating Turbocharger Oil Supply Tube Bolt
    GF0048669Courtesy of FORD MOTOR CO.
    NOTE: Roll the heat shield towards the cowl, then lift it up in the front and pull the shield forward to remove it.
  8. Remove the bolts and the turbocharger heat shield.
    9. Fig 5: Locating Turbocharger Heat Shield Bolts
    GF0048674Courtesy of FORD MOTOR CO.
  9. Remove the clamp at the turbocharger and position aside the exhaust downpipe.
    • Remove and discard the turbocharger gasket.
    10. Fig 6: Locating Exhaust Downpipe Clamp
    GF0048544Courtesy of FORD MOTOR CO.
    CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.
  10. Remove the banjo bolts and the sealing washers at the fuel cooler.
    • Discard the sealing washers.
    11. Fig 7: Locating Banjo Fittings & Sealing Washers From Fuel Cooler
    GF0048285Courtesy of FORD MOTOR CO.
  11. Remove the 3 bolts for the turbocharger actuator cooler.
    12. Fig 8: Locating Turbocharger Actuator Cooler Bolts
    GF0048675Courtesy of FORD MOTOR CO.
  12. Remove the bolts for the fuel cooler.
    13. Fig 9: Locating Fuel Cooler Mounting Bolts
    GF0048287Courtesy of FORD MOTOR CO.
  13. Remove the stud bolts for the fuel cooler.
    14. Fig 10: Locating Studs For Fuel Cooler
    GF0048288Courtesy of FORD MOTOR CO.
  14. Remove the retaining nuts for the fuel cooler.
    15. Fig 11: Locating Retaining Nuts For Fuel Cooler
    GF0048289Courtesy of FORD MOTOR CO.
  15. Remove the 3 bolts for the fuel cooling system expansion tank. Position aside the turbocharger actuator cooler, fuel cooler and coolant expansion tank.
    16. Fig 12: Locating Bolts From Fuel Cooler & Coolant Expansion Tank
    GF0048290Courtesy of FORD MOTOR CO.
  16. Remove the fuel cooler bracket.
    17. Fig 13: Locating Fuel Cooler Bracket
    GF0048676Courtesy of FORD MOTOR CO.
  17. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
    18. Fig 14: Locating Turbocharger Actuator Electrical Connector & Push Pin Retainer
    GF0048677Courtesy of FORD MOTOR CO.
  18. Remove the nut and position the oil level indicator and tube aside.
    19. Fig 15: Locating Retaining Nut From Oil Level Indicator Tube
    GF0048597Courtesy of FORD MOTOR CO.
    NOTE: Rear bolts shown, front bolts similar.
  19. Remove the bolts, the front fuel cooler bracket and the turbocharger crossover tube.
    20. Fig 16: Locating Turbocharger Crossover Tube Bolts
    GF0048678Courtesy of FORD MOTOR CO.
    NOTE: The seals in the crossover tube are one-time-use seals and must be installed new every time the connection is disassembled.
    NOTE: Large remover shown, small remover similar.
  20. Position the crossover tube in a soft-jawed vise. Using the special tool, remove the turbocharger crossover seal from each end of the crossover tube.
    21. Fig 17: Removing Turbocharger Crossover Seal From Each End Of Crossover Tube Using Special Tool (100-001, 303-1264)
    GF0048975Courtesy of FORD MOTOR CO.
  21. Disconnect the crankcase ventilation drain tube.
    22. Fig 18: Locating Crankcase Vent Oil Separator Tube From Crankcase Vent Oil Separator
    GF0048441Courtesy of FORD MOTOR CO.
    NOTE: Use one of the turbocharger crossover tube mounting holes in the LH valve cover bracket to mount the dial indicator with holding fixture. Position the tip of the dial indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the dial indicator, then push from the other end or pull the shaft.
  22. Using the special tool, check the high-pressure turbocharger axial end play. Compare the reading with the axial end play SPECIFICATIONS .
    23. Fig 19: Checking High-Pressure Turbocharger Axial End Play Using Special Tool (100-002)
    GF0048976Courtesy of FORD MOTOR CO.
    NOTE: Use one of the turbocharger crossover tube mounting holes in the LH valve cover bracket to mount the dial indicator with holding fixture. Position the tip of the dial indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The radial shaft moment check is done by pushing up and down on the turbocharger shaft. Zero the dial indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add the 2 readings together to get the total reading.
  23. Using the special tool, check the high-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement SPECIFICATIONS .
    24. Fig 20: Checking High-Pressure Turbocharger Radial Shaft Movement Using Special Tools (100-002, 308-021)
    GF0048977Courtesy of FORD MOTOR CO.
    NOTE: Use the valve cover stud to mount the dial indicator with holding fixture. Position the tip of the dial indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The axial end play check is done by pushing on the end of the turbocharger shaft. Zero the dial indicator, then push from the other end or pull the shaft.
  24. Using the special tool check the low-pressure turbocharger axial end play. Compare the reading with the axial end play SPECIFICATIONS .
    25. Fig 21: Checking Low-Pressure Turbocharger Axial End Play Using Special Tool (100-002)
    GF0048978Courtesy of FORD MOTOR CO.
    NOTE: Use a turbocharger bolt to mount the dial indicator with holding fixture. Position the tip of the dial indicator arm into the depression in the end of the turbocharger shaft.
    NOTE: The radial shaft moment check is done by pushing up and down on the turbocharger shaft. Zero the dial indicator, then push up on the shaft and take a reading, then push down on the shaft and take a reading. Add to 2 readings together to get the total reading.
  25. Using the special tool, check the low-pressure turbocharger radial shaft movement. Compare the total reading with the radial shaft movement SPECIFICATIONS .
    26. Fig 22: Checking Low-Pressure Turbocharger Radial Shaft Movement Using Special Tools (100-002, 308-021)
    GF0048979Courtesy of FORD MOTOR CO.
  26. Connect the crankcase ventilation drain tube.
    27. Fig 23: Locating Crankcase Vent Oil Separator Tube From Crankcase Vent Oil Separator
    GF0048441Courtesy of FORD MOTOR CO.
    NOTE: The seals in the crossover tube are one-time-use seals and must be installed new every time the connection is disassembled.
    NOTE: Large installer shown, small installer similar.
  27. Position the crossover tube in a soft-jawed vise. Using the special tool, install a new seal in each end of the turbocharger crossover tube.
    28. Fig 24: Identifying New Seal In Turbocharger Crossover Tube
    GF0048980Courtesy of FORD MOTOR CO.
    NOTE: Rear bolts shown, front bolts similar.
  28. Position the turbocharger crossover tube and the front fuel cooler bracket. Install the bolts for the turbocharger crossover tube.
    • Tighten to 31 Nm (23 lb-ft).
    29. Fig 25: Locating Turbocharger Crossover Tube Bolts
    GF0048678Courtesy of FORD MOTOR CO.
  29. Position back the oil level indicator and tube and install the nut.
    • Tighten to 31 Nm (23 lb-ft).
    30. Fig 26: Locating Retaining Nut From Oil Level Indicator Tube
    GF0048597Courtesy of FORD MOTOR CO.
  30. Connect the turbocharger actuator electrical connector and pin-type retainer.
    31. Fig 27: Locating Turbocharger Actuator Electrical Connector & Push Pin Retainer
    GF0048677Courtesy of FORD MOTOR CO.
  31. Position the fuel cooler bracket.
    32. Fig 28: Locating Fuel Cooler Bracket
    GF0048676Courtesy of FORD MOTOR CO.
  32. Position back the turbocharger actuator cooler, fuel cooler and coolant expansion tank. Install the 3 bolts for the fuel cooling system expansion tank.
    • Tighten to 9 Nm (80 lb-in).
    33. Fig 29: Locating Bolts From Fuel Cooler & Coolant Expansion Tank
    GF0048290Courtesy of FORD MOTOR CO.
  33. Install the retaining nuts for the fuel cooler.
    • Tighten to 19 Nm (168 lb-in).
    34. Fig 30: Locating Retaining Nuts For Fuel Cooler
    GF0048289Courtesy of FORD MOTOR CO.
    NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.
  34. Install the stud bolts for the fuel cooler.
    • Tighten to 25 Nm (18 lb-ft).
    35. Fig 31: Locating Studs For Fuel Cooler
    GF0048288Courtesy of FORD MOTOR CO.
  35. Install the bolts for the fuel cooler.
    • Tighten to 9 Nm (80 lb-in).
    36. Fig 32: Locating Fuel Cooler Mounting Bolts
    GF0048287Courtesy of FORD MOTOR CO.
    NOTE: Turbocharger actuator cooler removed for clarity.
  36. Position the turbocharger actuator cooler and install the bolts. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Finger tighten the bolts.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    37. Fig 33: Tightening Turbocharger Actuator Cooler Bolts In Sequence
    GF0048889Courtesy of FORD MOTOR CO.
    CAUTION: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the fuel system.
    CAUTION: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.
  37. Install the new sealing washers and banjo bolts at the fuel cooler.
    • Tighten to 25 Nm (18 lb-ft).
    38. Fig 34: Locating Banjo Fittings & Sealing Washers From Fuel Cooler
    GF0048285Courtesy of FORD MOTOR CO.
    NOTE: Install a new gasket on the turbocharger.
  38. Position back the exhaust downpipe and install the clamp.
    • Tighten to 15 Nm (133 lb-in).
    39. Fig 35: Locating Exhaust Downpipe Clamp
    GF0048544Courtesy of FORD MOTOR CO.
  39. Position the turbocharger heat shield and install the bolts.
    • Tighten to 11 Nm (97 lb-in).
    40. Fig 36: Locating Turbocharger Heat Shield Bolts
    GF0048674Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal.
  40. Position the turbocharger oil supply tube and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
    41. Fig 37: Locating Turbocharger Oil Supply Tube Bolt
    GF0048669Courtesy of FORD MOTOR CO.
    CAUTION: Use only banjo bolts with a green hex head. The green headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
    CAUTION: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
    NOTE: Use a back-up wrench to prevent the fittings from turning.
  41. Install 2 new copper sealing washers and the turbocharger oil supply tube banjo bolts.
    • Tighten to 38 Nm (28 lb-ft).
    • Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
    42. Fig 38: Locating Turbocharger Oil Supply Tube Banjo Fitting Bolts & Copper Sealing Washers
    GF0048668Courtesy of FORD MOTOR CO.
  42. Tighten the bolts for the exhaust downpipe at the OC.
    • Tighten to 40 Nm (30 lb-ft).
    43. Fig 39: Locating Exhaust Downpipe-To-Oxidation Catalytic Converter (OC) Pipe Bolts
    GF0048543Courtesy of FORD MOTOR CO.
  43. Position the auxiliary air intake in the vehicle.
    44. Fig 40: Locating Auxiliary Air Intake From Cowl
    GF0048542Courtesy of FORD MOTOR CO.
  44. Install the air cleaner outlet pipe and air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  45. Install the degas bottle module. For additional information, refer to ENGINE COOLING article.
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