Turbocharger(s) — removal and installation Ford F150
Warning: Wait until the engine is completely cool before beginning this procedure.
Note: The turbochargers must be handled with care and extreme cleanliness when they are removed, as they are precision high-speed components. When parts are disconnected from the turbochargers, the openings on the turbocharger must be protected from entry of dirt or chemicals. Use high-strength tape to cover them as components are detached.
Note: The procedure is virtually the same for either the left or right turbocharger.
Note: Some turbos are equipped with heat shields, some are not. Some replacement turbos do not have provisions for heat shields as the manufacturer stopped installing them during production.
Removal
1. The engine must be cold before removing the turbocharger(s). Before disconnecting any hoses, pipes or connections from the turbocharger, remove the heat insulation material.
2. Remove the engine cover
3. Loosen the wheel lug nuts, then raise and support the front of the vehicle on jackstands. Remove the wheel.
4. Drain the cooling system (see Tune-up and routine maintenance).
5. Remove the inner fender splash shield (see Body).
6. Remove the under-vehicle splash shield and transmission cover and/or skid plate (as equipped).
Remove the air intake tube (2.7L model shown).. .
. .. and the turbocharger inlet (A) and outlet (B) tubes
7. Loosen the clamps and remove the tube between the air intake tube to the air filter housing and the turbocharger inlet for the turbo to be serviced
8. Loosen the clamps and remove the tube between the intercooler and turbocharger outlet for the turbo to be serviced.
9. Tape off the openings on the turbocharger assembly.
10. On 2.7L or 2016 and earlier 3.5L turbocharged models, if servicing the passenger (right) turbocharger, remove the drivebelt (see Check the engine drivebelt). Remove the three air conditioning compressor mounting bolts and position the AC compressor aside (see Cooling, heating and air conditioning systems).
Warning: Do not disconnect the refrigerant lines!
2.7L models
Remove the exhaust flange nuts RH turbo on 2.7L model shown)
11. Remove the nuts attaching the exhaust flange to the turbocharger The studs should not be reused.
Identifying turbocharger components (RH turbo on 2.7L model shown)
12. Remove the fastener at the turbo and the clamp at the cylinder head to remove the coolant return line Discard the 0-ring and use a new one.
13. Disconnect the vacuum line at the waste gate and secure out of the way.
14. If servicing the driver (left) turbocharger, remove the nut from the upper front of the turbo mounting flange. The stud should not be reused.
15. Remove the fasteners at the top of the turbo and the front of the engine block and remove the oil supply line. Discard the 0-rings and use new ones.
16. Remove the fasteners at the bottom of the turbo and the side of the engine block and remove the oil return line. Discard the 0-rings and use new ones.
17. Remove the bolt securing the coolant supply line to the front of the engine block and disconnect the fitting from the block. Discard the 0-ring and use a new one.
18. Remove the nut(s) and bolt attaching the turbocharger mounting flange to the cylinder head and remove the turbocharger assembly. The coolant supply line will come out with the turbocharger so use care not to damage the line.
19. Remove the bolt securing the coolant supply line to the turbo. Discard the 0-ring and use a new one.
3.5L turbocharged models (2016 and earlier)
20. Remove the nuts and position the inter-cooler hose bracket aside to allow access to the AC compressor bolts.
21. Remove the nuts attaching the exhaust flange to the turbocharger. The studs should not be reused.
22. Disconnect the quick-connect fittings at the turbo and disconnect the coolant return line from the turbocharger.
23. Disconnect the vacuum line at the waste gate and secure out of the way.
24. Remove the bolt for the coolant and oil supply lines bracket on the side of the block.
25. Remove the bolts and disconnect the oil lines from the bottom of the turbocharger.
26. Disconnect the quick-connect fitting at the engine block for the coolant supply line.
27. Remove the bolts attaching the turbocharger mounting flange to the cylinder head and remove the turbocharger assembly. The coolant supply line will come out with the turbocharger so use care not to damage the line.
28. Disconnect the quick-connect fitting at the turbo to remove the coolant supply line.
3.5L turbocharged models
(2017 and later)
29. Remove the fasteners at the side of the turbo and the front of the engine block and remove the oil supply line. Discard the 0-rings and use new ones. It is recommended to discard the oil supply line and install a new one.
30. Unscrew and discard the oil supply line fitting and filter from the engine block. Use a new one at installation.
31. Remove the fasteners at the bottom of the turbo and the side of the engine block and remove the oil return line. Discard the 0-rings and use new ones.
32. Disconnect the wastegate electrical connector.
33. Remove and discard the nuts attaching the exhaust flange to the turbocharger. The nuts should not be reused.
34. Remove the bolts and disconnect the coolant supply and return line fittings from the engine block. Discard the 0-rings and use new ones.
35. Remove the Torx bolts attaching the turbocharger mounting flange to the exhaust manifold and remove the turbocharger assembly. The coolant supply and return lines come out with the turbocharger so use care not to damage the lines.
36. Remove the fasteners securing the coolant supply and return lines to the turbo. Discard the 0-rings and use a new ones.
Installation (all models)
37. Installation is the reverse of removal, noting the following:
- Use new gaskets at the turbo-to-exhaust junction on each side, and new gaskets and 0-rings where the oil and coolant supply and return lines connect to the turbocharger housing and engine block.
- Replace the filter on the engine block end of the oil supply line.
- Lubricate the oil line 0-rings with clean engine oil. Lubricate the coolant line 0-rings with coolant.
- It is recommended to use new studs, nuts and bolts for all exhaust-side com
- Install the coolant supply line to the turbo before installing the turbo to the cylinder head.
- When installing the turbocharger and coolant line, install the turbo mounting flange nuts and bolt loosely and connect the coolant supply line to the block, then tighten the flange nuts and bolt.
- Use anti-seize compound on the new turbocharger-to-exhaust nuts/bolts.
- Tighten all fasteners to the torque listed in this Chapter’s Specifications.
Refill and bleed the cooling system and install a new oil filter and fresh engine oil.