Ford BL3Z-6K682-C Turbocharger Assembly

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The engine must be cold before removing the turbocharger(s), and heat insulation material should be removed before disconnecting any hoses, pipes, or connections from the turbocharger. Drain the cooling system. When removing the right-hand turbocharger, first remove the drivebelt and the air conditioning compressor from the block, supporting the compressor out of the way with a length of wire or rope. To disconnect the Y-pipe and catalytic converters, support the transmission with a suitable jack and remove the transmission mount retainer and the crossmember; for 4WD models, raise the transfer case and remove the insulator, retainer plate, and crossmember. After removing the Y-pipe and converter assembly, reinstall the transmission insulator, retainer plate, and crossmember, tightening the fasteners just snug. Disconnect the vacuum hose at the wastegate, tagging and disconnecting the two other vacuum hoses and the coolant pipe connection. Disconnect the electrical connector at the turbocharger bypass valve, then disconnect the tube that feeds oil into the top of the center bearing housing for cooling, along with the pipe leading from the bottom of the center bearing housing to return oil to the engine's oil pan. Remove the duct from the air cleaner housing to the turbocharger and tape the openings, then remove the exhaust heat shield if equipped. Tape off any openings on the turbocharger assembly, remove the mounting bolt from the turbocharger-to-block bracket while holding the turbocharger, and then remove the turbocharger. Installation is the reverse of removal, using new gaskets at the turbo-to-exhaust junction on each side and new gaskets where the oil supply and return pipes connect to the turbocharger housing. Apply anti-seize compound on the new turbocharger-to-exhaust manifold bolts and on the Y-pipe-to-turbocharger junctions, tighten all fasteners to the specified torque, refill and bleed the cooling system, and install a new oil filter along with fresh engine oil.