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Turbocharger - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection > < Turbocharger

Focus 1999 (08.1998-12.2004)

Fuel Charging and Controls - Turbocharger - Turbocharger—1.8L Diesel (75 PS/90 PS) Focus 1999 (08/1998-12/2004)
Removal and Installation

Removal

All vehicles
  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Remove the air cleaner.
    For additional information, refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering, Removal and Installation).

  1. Disconnect the positive crankcase ventilation (PCV) hose from the valve cover.

  1. Remove the air cleaner outlet pipe.
    1. Slide the clip to release the pipe.
    1. Remove the pipe.

  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamp.
    Detach the charge air cooler intake pipe.
    1. Loosen the retaining clamp.
    1. Remove the nuts.
    • Discard the retaining clamp.

  1. Remove the charge air cooler intake pipe.

  1. NOTE:
    NOTE:Make a note of the orientation of the retaining clamp.
    Remove the charge air cooler intake pipe to turbocharger hose.
    • Discard the hose and the retaining clamps.

  1. Detach the exhaust gas recirculation (EGR) tube.
    • Remove the two bolts.
Vehicles with EGR cooler
  1. NOTE:
    NOTE:Make a note of the orientation of the EGR cooler clamp to make sure it is positioned in exactly the same position when installed. The hinge of the clamp should be obscured by the EGR cooler when viewed from the top of the engine. This is to allow access to the catalytic converter nuts.
    Remove and discard the EGR cooler clamp.
Vehicles without EGR cooler
  1. NOTE:
    NOTE:Make a note of the orientation of the EGR tube clamp to make sure it is positioned in exactly the same position when installed. The hinge of the clamp should be obscured by the EGR tube when viewed from the top of the engine. This is to allow access to the catalytic converter nuts.
    Remove and discard the EGR tube clamp.
All vehicles
  1. Remove the EGR tube.
Vehicles built up to 06/1999
  1. Disconnect the oil supply tube from the turbocharger.
    • Discard the sealing washers.
All vehicles
  1. Remove the catalytic converter.
    For additional information, refer to: Catalytic Converter - 1.8L Diesel (309-00 Exhaust System, Removal and Installation).

  1. Remove the engine roll restrictor bolt.
    • Move the engine as far forward as possible.
Vehicles with EGR cooler
  1. Detach the EGR cooler and secure it to one side.
Vehicles built up to 06/1999
  1. Disconnect the oil return tube.
    • Discard the O-ring seal.
Vehicles built 06/1999 onwards
  1. Disconnect the oil supply and return tube.
    • Discard the gasket.
All vehicles
  1. Lower the vehicle.

  1. Remove the exhaust manifold upper retaining bolts.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the catalytic converter support bracket from the cylinder block.

  1. Detach the turbocharger and exhaust manifold assembly.
    • Discard the gasket.

  1. Remove the turbocharger and exhaust manifold assembly.
    1. Move the engine as far forward as possible.
    1. Remove the turbocharger.

Installation

CAUTION:
CAUTION:Make sure that the inside of the charge air cooler intake hose and outlet hose ends are clean and free from any oil residue as this will reduce the installation grip of the hoses to the charge air cooler. Failure to follow this instruction may result in damage to the engine.
CAUTION:
CAUTION:Make sure that a new charge air cooler intake pipe to turbocharger hose and all new charge air cooler hose retaining clamps are installed. Failure to follow this instruction may result in damage to the engine.
All vehicles
  1. NOTE:
    NOTE:Install a new exhaust manifold gasket.
    NOTE:
    NOTE:Install a new oil return tube O-ring seal.
    NOTE:
    NOTE:Install new oil supply tube sealing washers.
    Install the exhaust manifold lower retaining bolts.

  1. Install the catalytic converter support bracket.
  1. Lower the vehicle.

  1. Install the exhaust manifold upper retaining nuts and bolts.
Vehicles built up to 06/1999
  1. NOTE:
    NOTE:Install new sealing washers.
    Connect the oil supply tube.
All vehicles
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Connect the oil return tube to the cylinder block.
Vehicles built 06/1999 onwards
  1. NOTE:
    NOTE:Make sure the oil supply and return tube gasket is correctly installed.
    Install a new oil supply and return tube gasket.

  1. Install the oil supply and return tube.
Vehicles built up to 06/1999
  1. NOTE:
    NOTE:Install a new O-ring seal.
    Install the oil return tube.
Vehicles with EGR cooler
  1. NOTE:
    NOTE:Do not tighten the bolts at this stage.
    Install the EGR cooler retaining bolts (hand tighten and then loosen 1.5 turns).
All vehicles
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Do not tighten the bolts at this point.
    Install the EGR tube (hand start the EGR tube to the ERG valve bolts).
Vehicles without EGR cooler
  1. CAUTION:
    CAUTION:To make sure of even compression of the EGR tube gasket when installing the tube clamp, the movement of the tube must not be restricted by the tube bolts.
    NOTE:
    NOTE:Make sure the clamp is installed in the same position as removed.
    Install the new EGR tube clamp.
Vehicles with EGR cooler
  1. CAUTION:
    CAUTION:To make sure of even compression of the EGR cooler gasket when installing the cooler clamp, the movement of the cooler must not be restricted by the cooler bolts.
    NOTE:
    NOTE:Make sure the EGR cooler clamp is installed in the same position as removed.
    Install a new EGR cooler clamp.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Tighten the EGR cooler to cylinder block retaining bolts.
All vehicles
  1. Install the engine roll restrictor bolt.
  1. Install the catalytic converter.
    For additional information, refer to: Catalytic Converter - 1.8L Diesel (309-00 Exhaust System, Removal and Installation).

  1. Tighten the EGR tube to EGR valve bolts.

  1. NOTE:
    NOTE:Make sure the retaining clamps are in the same position as when removed.
    Install a new charge air cooler intake pipe to turbocharger hose and retaining clamps.

  1. Connect the charge air cooler intake pipe.

  1. NOTE:
    NOTE:Install a new retaining clamp.
    NOTE:
    NOTE:Make sure the retaining clamp is in the same orientation as when removed.
    Install the charge air cooler intake pipe.
    1. Tighten the clamp.
    1. Tighten the nuts.

  1. Install the air cleaner outlet pipe.
    1. Install the pipe.
    1. Slide the clip to locate the pipe into position.

  1. Install the PCV hose to the valve cover.
  1. Install the air cleaner.
    For additional information, refer to: Air Cleaner (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Connect the battery ground cable.
    For additional information, refer to: Battery Disconnect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

Turbocharger - 1.8L Diesel, Vehicles With: Common Rail Fuel Injection > < Turbocharger