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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) >> Removal And Installation >> Turbocharger - Body Off >> Removal

Turbocharger - Body Off: Removal

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.
NOTE: It is recommended that this component be serviced with the vehicle body removed. Refer to BODY - 6.4L DIESEL . If the body cannot be removed, refer to the Turbocharger - Body On .
  1. Remove the body. For additional information, refer to FULL FRAME AND BODY MOUNTING article.
  2. Remove the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off procedure. For additional information, refer to EXHAUST SYSTEM article.
  3. Remove the clamp and disconnect the air cleaner outlet tube-to-crankcase vent oil separator hose at the vent oil separator.
  4. Loosen the clamp and remove the air cleaner outlet tube.
    5. 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.
  5. Remove the turbocharger oil supply tube banjo fitting bolts and copper sealing washers.
    • Discard the copper sealing washers.
  6. Remove the bolt and the turbocharger oil supply tube.
    • Remove and discard the O-ring seal.
  7. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
  8. Remove the 4 bolts for the turbocharger crossover tube and the front fuel cooler bracket.
  9. Remove the 5 bolts and the turbocharger heat shield.
  10. Remove the 2 bolts and hold downs for the turbocharger.
  11. Install the special tool.
    • Tighten to 20 Nm (177 lb-in).
    12. Fig 1: Identifying Special Tool (303-1266)
    GF0048684Courtesy of FORD MOTOR CO.
    CAUTION: Failure to use the turbocharger lifting bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure.
    CAUTION: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.
    NOTE: Use care when removing the turbocharger. The crossover tube should not be removed. The seals in the crossover tube are one-time-use seals and must be installed new.
  12. Using the special tool, remove the turbocharger assembly.
  13. Remove the turbocharger oil drain tubes.
    • Remove and discard the low-pressure drain tube.
    • Remove the high-pressure oil drain tube.
    • Remove and discard the 2 O-ring seals.
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