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303-04D Fuel Charging and Controls - Turbocharger|Specifications > < Turbocharger - 1.8L Diesel (75 PS-90 PS)

Focus 1999 (08.1998-12.2004)

Fuel Charging and Controls - Turbocharger - Turbocharger—1.8L Diesel, Vehicles With: Common Rail Fuel Injection 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. Remove the engine cover.

  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) valve tube.
    • Remove the two bolts.
Vehicles with exhaust gas recirculation (EGR) cooler
  1. Remove the EGR cooler to exhaust manifold retaining bolts and remove the EGR cooler.
    • Discard the gasket.
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Remove the exhaust manifold to EGR valve tube retaining bolts.
All vehicles
  1. Disconnect the vacuum diaphragm unit vacuum line.
  1. Remove the EGR tube.
  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 exhaust gas recirculation (EGR) cooler
  1. Detach the EGR cooler and secure it to one side.
All vehicles
  1. NOTE:
    NOTE:On vehicles built 07/2004 onwards, the sealing washers cannot be removed from the turbocharger oil supply tube.
    Disconnect the oil supply and return tubes.
    1. Disconnect the oil supply tube.

        2. 1. On vehicles built up to 06/2004, discard the sealing washers.

    1. Disconnect the oil return tube.

        2. 1. Discard the O-ring seal.

  1. Remove the oil return line from the cylinder block.
  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 exhaust manifold gasket.

  1. Remove the turbocharger and exhaust manifold assembly.
    1. Move the engine as far forward as possible.
    1. Remove the turbocharger.
Vehicles built 07/2004 onwards
  1. Remove and discard the turbocharger oil supply tube.
    • Remove the turbocharger oil supply tube retaining bracket bolt.

Installation

Vehicles built 07/2004 onwards
  1. Install a new turbocharger oil supply tube.
    • Install the turbocharger oil supply tube retaining bracket bolt.
All vehicles
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.
NOTE:
NOTE:Install a new exhaust manifold gasket.
NOTE:
NOTE:Install a new oil return tube O-ring seal.
NOTE:
NOTE:On vehicles built up to 06/2004, install new oil supply tube sealing washers.
  1. NOTE:
    NOTE:Remove and discard the blanking caps from the turbocharger and exhaust manifold assembly open ports.
    Install the turbocharger and exhaust manifold assembly.
    1. Move the engine as far forward as possible.
    1. Install the turbocharger.

  1. 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.

  1. Connect the vacuum diaphragm unit vacuum line.
  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.

  1. Install the oil supply and return tubes.
      NOTE:
      NOTE:Install a new O-ring seal.
    1. Install the oil return tube.
      NOTE:
      NOTE:On vehicles built up to 06/2004, install new sealing washers.
    1. Install the oil supply tube.
Vehicles with exhaust gas recirculation (EGR) cooler
  1. NOTE:
    NOTE:Do not tighten the bolts at this stage.
    Install the EGR cooler retaining bolts (finger tighten and then loosen 1.5 turns).
All vehicles
  1. Lower the vehicle.

  1. NOTE:
    NOTE:Do not tighten the bolts at this stage.
    Install the EGR valve tube (finger start the EGR valve tube to the EGR valve bolts).
Vehicles with exhaust gas recirculation (EGR) cooler
  1. Install the EGR cooler to the exhaust manifold.
    • Install a new EGR cooler to exhaust manifold gasket.
  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 exhaust manifold retaining bolts.
Vehicles without exhaust gas recirculation (EGR) cooler
  1. Install the exhaust manifold to EGR valve tube retaining bolts.
All vehicles
  1. Install the support insulator 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 valve tube to EGR valve bolts.

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

  1. CAUTION:
    CAUTION:Make sure that the inside of the charge air cooler intake pipe is free from any foreign material. Failure to follow this instruction may result in damage to the turbocharger.
    CAUTION:
    CAUTION:Make sure that the inside of the charge air cooler intake pipe end is clean and free from any oil residue as this will reduce the installation grip of the hose to the turbocharger. Failure to follow this instruction may result in premature damage to the turbocharger.
    Connect the charge air cooler intake pipe.

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

  1. CAUTION:
    CAUTION:Make sure that the inside of the air cleaner outlet pipe is free from any foreign material. Failure to follow this instruction may result in damage to the turbocharger.
    CAUTION:
    CAUTION:Make sure that the inside of the air cleaner outlet pipe end is clean and free from any oil residue as this will reduce the installation grip of the hose to the turbocharger. Failure to follow this instruction may result in premature damage to the turbocharger.
    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 engine 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).

303-04D Fuel Charging and Controls - Turbocharger|Specifications > < Turbocharger - 1.8L Diesel (75 PS-90 PS)