2003 F-Super Duty /Excursion Workshop Manual
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1 Page 1 of 7 SECTION F: Fuel Charging and Controls Turbocharger, 6.0L Diesel 2003 F-Super Duty /Excursion Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 03/14/2005 Turbocharger Printable View (504 KB) Special Tool(s) Disconnect Tool, Quick-Release Coupling Material Item SAE 15W-40 Super Duty Motor Oil XO-15W40-QSD or equivalent Specification WSS-M2C171-D Removal 1. Remove the turbocharger intake tube. For additional information, refer to Turbocharger Intake Tube in this section. 2. Disconnect the charge air cooler inlet pipe. 3. Remove the push pins. 4. Disconnect the two wiring harness push pins and position out of the way. 5. Disconnect the turbocharger variable hydraulic control valve electrical connector. 6. Remove the bolts for the oil supply tube.
2 Page 2 of 7 Remove and discard the gasket. 7. Remove the bolt and the wire retainer. 8. Using the special tool, remove the oil feed tube. 9. Remove the marmon clamp from the turbocharger outlet. 10. Remove the marmon clamp from the turbocharger inlet. 11. Loosen the exhaust inlet pipe-to-egr cooler clamp.
3 Page 3 of Loosen the LH exhaust inlet pipe-to-exhaust manifold nuts. 13. Loosen the RH exhaust inlet pipe-to-exhaust manfold nuts. 14. NOTE: Turbocharger shown removed for clarity. Remove the rear turbocharger mounting bolt. 15. NOTE: Left side shown, right side similar. Remove the front mounting bolts. 16. Position the turbocharger and remove the turbocharger drain tube. Remove and discard the drain tube O-rings.
4 Page 4 of Remove the turbocharger. Installation 1. Position the turbocharger on the turbocharger pedestal. Place the turbocharger onto the mounting bracket. Make sure the exhaust inlet pipe is correctly aligned to the turbocharger. If it is not, loosen the mounting bracket and reposition the turbocharger and the mounting bracket for correct alignment. Complete the turbocharger installation. 2. NOTE: Install new O-rings and apply clean engine oil. Position the turbocharger and install the turbocharger drain tube. 3. Install the turbocharger and the rear mounting bolt. 4. Install the turbocharger front mounting bolts. 5. Install the turbocharger inlet marmon clamp. 6. Position the clamp and tighten to specification.
5 Page 5 of 7 7. Make sure the exhaust inlet pipe is correctly aligned to the exhaust manifolds. Using hand tools, alternately tighten the nuts to draw the pipe to the exhaust manifold. There should be an equal gap spacing between the pipe flange and the exhaust manifold flange at the top and bottom bolts. 8. NOTE: LH side shown, RH side similar Alternately tighten the exhaust inlet pipe-to-exhaust manifold nuts to specification. 9. Install the turbocharger exhaust marmon clamp. 10. Install the oil feed tube. 11. Position the wire retainer and install the bolt.
6 Page 6 of Prelubricate the oil inlet hole of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearing with oil. 13. Position the oil feed tube and install the bolts. Install a new gasket. 14. Connect the turbocharger variable vane hydraulic control valve electrical connector. 15. Position the wiring harness and connect the push pins. 16. Install the push pins. 17. Connect the charge air cooler inlet pipe.
7 Page 7 of Install the turbocharger intake tube. For additional information, refer to Turbocharger Intake Tube in this section.
2004 F-150 Workshop Manual
Page 1 of 8 SECTION 303-01B: Engine 5.4L (3V) 2004 F-150 Workshop Manual REMOVAL Procedure revision date: 02/10/2004 Engine Printable View (943 KB) Special Tool(s) Modular Engine Lift Bracket 303-F047
2006 F-Super Duty Workshop Manual. Installation. All vehicles. Install the glow plug. Tighten to 19 Nm (14 lb-ft).
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SECTION D Fuel Charging and Controls Turbocharger
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SECTION D Fuel Charging and Controls Turbocharger
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DESCRIPTION AND OPERATION
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Page 1 of 7 SECTION 303-04D: Fuel Charging and Controls Turbocharger 2006 F-Super Duty 250-550 Workshop Manual GENERAL PROCEDURES Procedure revision date: 10/09/2009 Turbocharger Reconditioning Printable
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2008 F-Super Duty Workshop Manual
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