Loosen two bolts retaining turbocharger exhaust inlet pipe to right exhaust manifold.
Section 03-04E: Turbocharger, 7.3L Diesel Engine | 1996 F-250, F-350 and F-Super Duty Workshop Manual |
| Description | Tool Number |
|---|---|
| Fuel/Oil/Turbo Protector Cap Set | T94T-9395-AH |
Removal
Disconnect battery ground cable (14301).
Remove two air intake tube assembly bolts, clamps at turbocharger, crankcase breather assembly and engine air cleaner (ACL) (9600), and air intake tube and hoses.
Remove exhaust outlet marmon clamp from turbocharger.
Raise vehicle.
Remove engine charge exhaust pipe bolt from transmission, if so equipped.
Remove bolts and nuts from catalytic converter to engine charge exhaust pipe, if so equipped.
Loosen two bolts retaining turbocharger exhaust inlet pipe to left exhaust manifold (9430).
NOTE: This step applies only to automatic transmission.
Remove bolts retaining left turbocharger exhaust inlet pipe to turbocharger exhaust inlet adapter.
Loosen two bolts retaining turbocharger exhaust inlet pipe to right exhaust manifold.
Remove lower bolt retaining right turbocharger exhaust inlet pipe to turbocharger exhaust inlet adapter.
Lower vehicle.
NOTE: This step applies only to automatic transmission.
Remove upper bolts retaining right and left turbocharger exhaust inlet pipes to turbocharger exhaust inlet adapter.
Remove right engine lift hook and bolt.
Loosen air inlet hose clamp at turbocharger. Disconnect hose and lay aside.
NOTE: Steps 15 and 16 apply only to automatic transmission.
Loosen four intake manifold hose clamps, and one clamp retaining compressor manifold to turbocharger.
| Item | Part Number | Description |
|---|---|---|
| 1 | — | Compressor Housing (Part of 6K682) |
| 2 | 8287 | Hose Clamp |
| 3 | 8287 | Manifold Hose Clamp |
| 4 | 1820075C1 | Intake Manifold Hose |
| 5 | 6K889 | Compressor Manifold |
Remove compressor manifold.
Remove four bolts retaining turbocharger pedestal assembly to cylinder block.
Remove turbocharger assembly and disconnect electrical connectors.
NOTE: If turbocharger is not being removed for service, install Fuel/Oil/Turbo Protector Cap Set T94T-9395-AH.
Remove oil gallery O-rings.
Installation
Install new oil gallery O-rings.
Connect turbocharger electrical connectors and install turbocharger assembly.
Install four bolts retaining turbocharger pedestal assembly to engine block. Tighten to 24 Nm (18 lb-ft).
Loosely install bolts retaining right and left turbocharger exhaust inlet pipes to turbocharger exhaust inlet adapter.
Install compressor manifold, intake manifold hoses and clamps. Make sure compressor outlet seal is in position.
Install right engine lift hook and bolt.
Raise vehicle.
Tighten two right and left lower bolts (retaining turbocharger exhaust inlet pipes to turbocharger exhaust inlet adapter) to 24 Nm (18 lb-ft).
Tighten four right and left bolts and nuts (retaining turbocharger exhaust inlet pipes to exhaust manifolds) to 24 Nm (18 lb-ft).
Install catalytic converter to engine charge exhaust pipe bolts and nuts.
Lower vehicle.
Tighten two right and left upper bolts (retaining turbocharger exhaust inlet pipes to turbocharger exhaust inlet adapter) to 24 Nm (18 lb-ft).
Install exhaust outlet marmon clamp to turbocharger.
Install air intake tube and hose assembly, two bolts and clamps.
Connect battery ground cable.