6.0l Turbocharger Remove and Install

303-04D-1 303-04D-1Fuel Charging and Controls — Turbocharger

REMOVAL AND INSTALLATION

Turbocharger

Special Tool(s)

Disconnect Tool, Quick-ReleaseCoupling303-755

Material

Item Specification 4. Disconnect the two wiring harness push pinsand position aside.SAE 15W-40 Super Duty WSS-M2C171-D

Motor OilXO-15W40-QSD orequivalent

High Temperature Nickel ESE-M12A4-AAnti-Seize LubricantXL-2

Removal

All vehicles

1. Remove the turbocharger intake tube. Foradditional information, refer to TurbochargerIntake Tube in this section.

5. Disconnect the turbocharger variable vane2. Disconnect the charge air cooler inlet pipe. hydraulic control valve electrical connector.

3. Remove the push pins.

Copyright 2003, Ford Motor CompanyLast updated: 3/14/2005 2004 Excursion, F-Super Duty 250-550, 12/2004


REMOVAL AND INSTALLATION (Continued)

6. Remove the bolts for the oil supply tube.

• Remove and discard the gasket.

10. Loosen the exhaust inlet pipe-to-EGR coolerclamp.

7. Remove the bolt and the wire retainer.

11. Loosen the LH exhaust inlet pipe-to-exhaustmanifold nuts.

8. Remove the marmon clamp from theturbocharger outlet.

9. Remove the marmon clamp from theturbocharger inlet.

2004 Excursion, F-Super Duty 250-550, 12/2004



Late build12. Loosen the RH exhaust inlet pipe-to-exhaustmanfold nuts.

15. Remove the bolt and turbocharger oil supplytube.

• Remove and discard the O-ring.

Early build

13. Using the special tool, remove the oil feed tube.

16. Remove the rear turbocharger mounting bolt.

14. NOTE: Turbocharger shown removed forclarity. All vehiclesRemove the rear turbocharger mounting bolt.

17. NOTE: Left side shown, right side similar.

Remove the front mounting bolts.




Late build18. Position the turbocharger and remove theturbocharger drain tube.

NOTE: Apply High Temperature Nickel Anti-Seize• Remove and discard the drain tube O-rings.Lubricant to the bolt threads prior to installation.

3. Install the turbocharger and the rear mountingbolt.

19. Remove the turbocharger.

Installation

4. NOTE: Install a new O-ring and apply cleanAll vehiclesengine oil.

Install the oil supply tube.1. Position the turbocharger on the turbochargerpedestal. • Position the locking bracket and install the

bolt.• Place the turbocharger onto the mountingbracket. Make sure the exhaust inlet pipe iscorrectly aligned to the turbocharger. If it isnot, loosen the mounting bracket andreposition the turbocharger and the mountingbracket for correct alignment. Complete theturbocharger installation.

2. NOTE: Install new O-rings and apply cleanengine oil.

Position the turbocharger and install theturbocharger drain tube.




Early build

NOTE: Apply High Temperature Nickel Anti-SeizeLubricant to the bolt threads prior to installation.

5. Install the turbocharger and the rear mountingbolt.

8. Install the turbocharger inlet marmon clamp.

6. Install the oil feed tube.

9. Position the clamp and tighten to specification.

All vehicles

NOTE: Apply High Temperature Nickel Anti-SeizeLubricant to the bolt threads prior to installation.

7. Install the turbocharger front mounting bolts.




10. Make sure the exhaust inlet pipe is correctly 13. Position the wire retainer and install the bolt.aligned to the exhaust manifolds. Using handtools, alternately tighten the nuts to draw thepipe to the exhaust manifold. There should bean equal gap spacing between the pipe flangeand the exhaust manifold flange at the top andbottom bolts.

14. Prelubricate the oil inlet hole of theturbocharger assembly with clean engine oil andspin the compressor wheel several times to coatthe bearing with oil.

15. Position the oil feed tube and install the bolts.11. NOTE: LH side shown, RH side similar. • Install a new gasket.

Alternately tighten the exhaust inletpipe-to-exhaust manifold nuts to specification.

16. Connect the turbocharger variable vanehydraulic control valve electrical connector.

12. Install the turbocharger exhaust marmon clamp.




17. Position the wiring harness and connect the 19. NOTE: If there is any oil residue, clean bothpushpins. connecting ports and the inside surface of the

charge air cooler duct to prevent the duct fromblowing off.

Connect the charge air cooler inlet duct.

18. Install the pushpins.

20. Install the turbocharger intake tube. Foradditional information, refer to TurbochargerIntake Tube in this section.


6.0l Turbocharger Remove and Install

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