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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 On >> Removal

Turbocharger - Body On: 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.
CAUTION: Position a suitable material in front of the charge air cooler (CAC) or damage to the CAC may occur.
NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to the Turbocharger - Body Off .
  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. For additional information, refer to ENGINE COOLING article.
  3. Remove the air cleaner assembly and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  4. Remove the auxiliary air intake hose.
    5. Fig 1: Locating Auxiliary Air Intake From Cowl
    GF0048542Courtesy 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.
  5. Remove the turbocharger oil supply tube banjo bolts and copper sealing washers.
    • Discard the copper sealing washers.
    6. Fig 2: Locating Turbocharger Oil Supply Tube Banjo Fitting Bolts & Copper Sealing Washers
    GF0048668Courtesy of FORD MOTOR CO.
  6. Remove the bolt and the turbocharger oil supply tube.
    • Remove and discard the O-ring seal.
    • Plug or cap the openings as needed.
    7. Fig 3: Locating Turbocharger Oil Supply Tube Bolt
    GF0048669Courtesy of FORD MOTOR CO.
    NOTE: Roll the heat shield towards the cowl, then lift up in the front and remove forward.
  7. Remove the bolts and the turbocharger heat shield.
    8. Fig 4: Locating Turbocharger Heat Shield Bolts
    GF0048674Courtesy 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.
  8. Remove the banjo bolts and the sealing washers at the fuel cooler.
    • Discard the sealing washers.
    9. Fig 5: Locating Banjo Fittings & Sealing Washers From Fuel Cooler
    GF0048285Courtesy of FORD MOTOR CO.
  9. Remove the 3 bolts for the fuel cooling system expansion tank.
    10. Fig 6: Locating Bolts From Fuel Cooler & Coolant Expansion Tank
    GF0048290Courtesy of FORD MOTOR CO.
  10. Remove the bolts for the fuel cooler.
    11. Fig 7: Locating Fuel Cooler Mounting Bolts
    GF0048287Courtesy of FORD MOTOR CO.
  11. Remove the stud bolts for the fuel cooler.
    12. Fig 8: Locating Studs For Fuel Cooler
    GF0048288Courtesy of FORD MOTOR CO.
  12. Remove the 2 nuts for the fuel cooler.
    13. Fig 9: Locating Retaining Nuts For Fuel Cooler
    GF0048289Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts for the turbocharger actuator cooler. Position the fuel cooler, fuel cooling system expansion tank and turbocharger actuator cooler aside.
    14. Fig 10: Locating Turbocharger Actuator Cooler Bolts
    GF0048675Courtesy of FORD MOTOR CO.
  14. Remove the fuel cooler bracket.
    15. Fig 11: Locating Fuel Cooler Bracket
    GF0048676Courtesy of FORD MOTOR CO.
  15. Disconnect the turbocharger actuator electrical connector and pin-type retainer.
    16. Fig 12: Locating Turbocharger Actuator Electrical Connector & Push Pin Retainer
    GF0048677Courtesy of FORD MOTOR CO.
    NOTE: Engine removed from art for clarity.
  16. Remove the RH turbocharger inlet pipe-to-EGR-oxidation catalytic converter (OC) pipe bolts and the EGR-OC-to-turbocharger bracket bolts.
    • Discard the bolts.
    17. Fig 13: Locating EGR-OC-to-Bracket Bolts
    GF0048548Courtesy of FORD MOTOR CO.
  17. Remove the RH splash shield. For additional information, refer to FRONT END BODY PANELS article.
  18. Remove the exhaust gas recirculation temperature (EGRT) sensor from the RH turbocharger inlet pipe.
    19. Fig 14: Locating Exhaust Gas Recirculation Temperature (EGRT) Sensor From RH Turbocharger Inlet Pipe
    GF0048549Courtesy of FORD MOTOR CO.
    NOTE: Index-mark the drive shaft prior to disconnecting from the axle.
  19. If equipped, remove the 4 bolts, straps and position aside the front drive shaft aside.
    20. Fig 15: Locating Front Drive Shaft Bolts
    GF0048990Courtesy of FORD MOTOR CO.
  20. Disconnect the exhaust pressure (EP) sensor tube from the EGR-OC pipe.
    21. Fig 16: Locating Exhaust Pressure (EP) Sensor Tube From EGR-OC Pipe
    GF0048545Courtesy of FORD MOTOR CO.
  21. Remove the EP sensor tube fitting from the EGR-OC pipe.
    22. Fig 17: Locating EP Tube Assembly
    GF0048681Courtesy of FORD MOTOR CO.
  22. Remove the EGR-OC pipe bracket-to-bracket bolt and washer. Remove the cylinder head bracket-to-cylinder head bolt, washers and the bracket.
    • Discard the bolts.
    23. Fig 18: Locating EGR-OC Pipe Bracket-To-Cylinder Head Bracket Bolt & Washer
    GF0048546Courtesy of FORD MOTOR CO.
  23. Remove the EGR-OC-to-EGR cooler bolts.
    • Discard the bolts and gasket.
    24. Fig 19: Locating EGR-OC-To-EGR Cooler Bolts
    GF0048547Courtesy of FORD MOTOR CO.
  24. Loosen the exhaust downpipe-to-OC pipe bolts.
    25. Fig 20: Locating Exhaust Downpipe-To-Oxidation Catalytic Converter (OC) Pipe Bolts
    GF0048543Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  25. Remove and discard the 6 LH and RH turbocharger inlet pipes-to-exhaust manifold nuts.
    26. Fig 21: Locating LH Turbocharger Inlet Pipe-To-Exhaust Manifold Nuts
    GF0048688Courtesy of FORD MOTOR CO.
  26. Remove and discard the exhaust downpipe clamp. Position aside the exhaust downpipe.
    • Remove and discard the exhaust downpipe gasket.
    27. Fig 22: Locating Exhaust Downpipe Clamp
    GF0048544Courtesy of FORD MOTOR CO.
  27. Remove the 6 turbocharger inlet pipe bolts and EGR-OC-to-turbocharger bracket.
    • Discard the bolts and gaskets.
    28. Fig 23: Locating Exhaust Manifolds-To-Turbocharger Inlet Pipe Joints
    GF0048682Courtesy of FORD MOTOR CO.
  28. Remove the 3 LH turbocharger inlet pipes-to-exhaust manifold studs and gasket. Remove the LH turbocharger inlet pipe.
    • Discard the studs and gasket.
    29. Fig 24: Locating LH Turbocharger Inlet Pipe-To-Exhaust Manifold Gasket & Lower Studs
    GF0048689Courtesy of FORD MOTOR CO.
  29. Remove the 2 outer RH turbocharger inlet pipes-to-exhaust manifold studs.
    • Discard the studs.
    30. Fig 25: Locating RH Turbocharger Inlet Pipe-To-Exhaust Manifold Studs
    GF0048551Courtesy of FORD MOTOR CO.
  30. Loosen the clamps and remove the charge air cooler (CAC) tube flex coupling.
    31. Fig 26: Locating Clamps & Charge Air Cooler (CAC) Tube Flex Coupling
    GF0048991Courtesy 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.
  31. Remove the fuel filter module cover, fuel filter and, using a suitable suction device, remove the fuel from the fuel filter module.
    • Cover the fuel filter housing with a covering to prevent foreign material from entering the fuel system.
    32. Fig 27: Identifying Fuel Filter Module Cover
    GF0048992Courtesy 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.
  32. Remove the banjo bolt, copper sealing washer and fuel cooler to fuel filter module tube.
    • Discard the copper sealing washer.
    33. Fig 28: Identifying Banjo Bolt, Copper Sealing Washer & Fuel Cooler To Fuel Filter Module Tube
    GF0048993Courtesy of FORD MOTOR CO.
  33. Remove the nut and position the oil level indicator and tube aside.
    34. Fig 29: Locating Retaining Nut From Oil Level Indicator Tube
    GF0048597Courtesy of FORD MOTOR CO.
  34. Remove the bolts for the turbocharger crossover tube.
    • Remove the front fuel cooler bracket.
    35. Fig 30: Locating Turbocharger Crossover Tube Bolts
    GF0048678Courtesy of FORD MOTOR CO.
  35. Remove the bolt for the engine wiring harness.
    36. Fig 31: Locating Engine Wiring Harness Bolt
    GF0048994Courtesy 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.
    NOTE: Use a commercially available disconnect tool and a screwdriver to release the fuel tube.
  36. Disconnect the fuel injection pump supply tube at the fuel filter module.
    37. Fig 32: Locating Fuel Injection Pump Supply Tube From Fuel Filter Module
    GF0048953Courtesy of FORD MOTOR CO.
  37. Remove and discard the oil filter element and O-ring seal.
    38. Fig 33: Locating Oil Filter Cap & Oil Filter Element
    GF0048670Courtesy of FORD MOTOR CO.
  38. Remove the 4 Torx bolts and the oil filter housing.
    39. Fig 34: Locating Oil Filter Housing Bolts
    GF0048671Courtesy of FORD MOTOR CO.
  39. Remove the screw and the oil filter return tube assembly.
    40. Fig 35: Locating Oil Filter Return Tub Screw
    GF0048672Courtesy of FORD MOTOR CO.
  40. Remove and discard the oil filter base gasket and seal.
    • Cover the oil cooler to prevent foreign material from entering.
    41. Fig 36: Locating O-Ring Seal & Gasket
    GF0048673Courtesy of FORD MOTOR CO.
  41. Disconnect the EGR valve electrical connector.
    42. Fig 37: Locating EGR Valve Electrical Connector
    GF0048995Courtesy of FORD MOTOR CO.
  42. Remove the bolts and the hold downs for the turbocharger.
  43. Install the special tool.
    • Tighten to 20 Nm (177 lb-in).
    44. Fig 38: Identifying Special Tool (303-1266)
    GF0048988Courtesy 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.
  44. With the help of an assistant, using the heavy duty lifting crane, remove the turbocharger assembly.
    • Remove and discard the RH turbocharger inlet pipe gasket at the RH exhaust manifold.
  45. 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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