Ford FT4Z-6K682-A Turbocharger Assembly

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To remove the turbocharger, start by raising the vehicle and supporting it securely on jackstands. Then, remove the catalytic converter and the charge air cooler inlet tube. Drain the cooling system. For 2014 and earlier models, remove the turbocharger heat shield and disconnect the coolant and oil lines. Disconnect the vacuum lines and electrical connectors to the turbocharger. Detach the coolant lines from the turbocharger. Remove the oil drain tube and discard the gasket. Remove the turbocharger mounting nuts and carefully maneuver the turbocharger out of the vehicle. Use a stud removal tool to remove the turbocharger studs from the cylinder head. For 2015 and later four-cylinder models, remove the cowl panel and drain the cooling system. Remove the right-front wheel and the engine lower shield. Disconnect the turbocharger bypass valve electrical connector and detach the harness retainer. Disconnect the turbocharger bypass hose clamp and hose. Remove the turbocharger outlet pipe and the turbocharger inlet pipe. Remove the turbocharger coolant tubes and replace the banjo bolt sealing washers and tube O-rings. Remove the upper turbocharger mounting nuts, heat shield, and oil supply tube. Replace the turbocharger oil filter. Disconnect the wastegate control hose and remove the turbocharger oil return tube. Lower the engine slightly and disconnect the CHT sensor electrical connector and turbocharger control valve vacuum tube retainers. Remove the remaining turbocharger mounting nuts and remove the turbocharger. For 2015 and later V6 models, drain the cooling system and remove the outlet pipes from the air filter housing. Remove the engine lower shield. For the left-side turbocharger, remove the outlet pipe, heat shield, and inlet pipe. For the right-side turbocharger, remove the cowl panel, right front wheel, and lower Charge Air Cooler intake pipe. Remove the turbocharger oil supply tube, oil filter, coolant tube, wastegate control hose, and oil return tube. Remove the turbocharger coolant supply tube bolt and the turbocharger mounting nuts and bolt. Inspect and replace any necessary studs, bolts, and nuts. Install the turbocharger(s) and tighten the new nuts/bolts. Install the new oil drain tube and gaskets. Install new sealing washers for the oil feed line and coolant line. Complete the installation in reverse order and refill the cooling system and change the engine oil and filter.