Disassembly And Assembly: Turbocharger: Disassembly

All turbochargers 

1. Remove the turbocharger crossover tube.
Fig 1: Locating Turbocharger Crossover Tube
Courtesy of FORD MOTOR CO.
NOTE: The seals in the turbocharger 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.
2. 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.
Fig 2: Removing Turbocharger Crossover Seal From Each End Of Crossover Tube Using Special Tool (100-001, 303-1264)
Courtesy of FORD MOTOR CO.
3. Remove the turbocharger tube.
Fig 3: Locating Turbocharger Tube
Courtesy of FORD MOTOR CO.

Turbocharger with press-fit linkage 

NOTE: Remove the turbocharger actuator only if the high-pressure turbocharger is being serviced.
NOTE: It will be necessary to position the linkage to gain access to the clip. A section of rubber hose can be used to hold the linkage in position while removing the clip.
4. Remove the clip for the turbocharger actuator linkage.
Fig 4: Locating Clip From Turbocharger Actuator Linkage
Courtesy of FORD MOTOR CO.
5. Using the special tool, disconnect the turbocharger actuator linkage.
Fig 5: Detaching Turbocharger Actuator Rod From Turbocharger Using Special Tool (205-D035)
Courtesy of FORD MOTOR CO.

Turbocharger with slip-fit linkage 

NOTE: Remove the turbocharger actuator only if the high-pressure turbocharger is being serviced.
6. Remove the nut and disconnect the turbocharger actuator linkage.
Fig 6: Locating Turbocharger Actuator Linkage Nut
Courtesy of FORD MOTOR CO.

All turbochargers 

7. Remove the bolts and the turbocharger actuator.
Fig 7: Locating Turbocharger Actuator Bolts
Courtesy of FORD MOTOR CO.
8. Remove the turbocharger actuator insulator.
Fig 8: Locating Turbocharger Actuator Insulator
Courtesy of FORD MOTOR CO.
9. Measure the gap between the 2 turbochargers prior to separating them and record the gap. Using an appropriate tool, carefully separate the 2 turbochargers.
Fig 9: Measuring Gap Between 2 Turbochargers Prior To Separating Them
Courtesy of FORD MOTOR CO.
10. Remove and discard the low-pressure to high-pressure turbocharger seal and gasket.
Fig 10: Locating Low-Pressure To High-Pressure Turbocharger Seal & Gasket
Courtesy of FORD MOTOR CO.
NOTE: The seal in the turbocharger is a one-time-use seal and must be installed new every time the connection is disassembled.
11. Using the special tool, remove the low-pressure turbocharger tube seal from the turbocharger.
Fig 11: Removing Low-Pressure Turbocharger Tube Seal From Turbocharger Using Special Tool (100-001, 303-1264)
Courtesy of FORD MOTOR CO.
12. If necessary, remove the turbocharger oil supply standoffs.
    • Remove and discard the O-ring seal.
Fig 12: Locating Turbocharger Oil Supply Standoffs
Courtesy of FORD MOTOR CO.