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Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K > < Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS)

Focus 2004.75 (07.2004-)

Fuel Charging and Controls - Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel/1.8L Duratorq-TDCi (Lynx) Diesel/2.0L Duratorq-TDCi (DW) Diesel - Turbocharger—1.6L Duratorq-TDCi (DV) Diesel (110 PS) Focus 2004.75 (07/2004-)
Removal and Installation

  1. Disconnect the battery ground cable. For additional information, refer to Section  414-01 Battery, Mounting and Cables.

  1. Remove the engine upper cover.

  1. Remove the turbocharger outlet hose.
  1. Raise and support the vehicle. For additional information, refer to Section  100-02 Jacking and Lifting.

  1. Detach the charge air cooler intake hose from the charge air cooler intake pipe.

  1. Remove the charge air cooler intake pipe.

7. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Catalytic converter heat shield lower retaining bolts
See Installation Detail
2
-
Catalytic converter heat shield
See Removal Detail

 
Item
Part Number
Description
3
-
Turbocharger outlet pipe
See Removal Detail
4
-
Exhaust manifold heat shield
5
-
Turbocharger to air cleaner outlet pipe retaining clamp
6
-
Turbocharger oil supply tube
7
-
Turbocharger oil supply tube union copper washers
8
-
Turbocharger variable vain vacuum control supply pipe
9
-
Turbocharger variable vain vacuum control electrical connector
10
-
Oil return hose retaining clamp
See Removal Detail
11
-
Catalytic converter to turbocharger clamp
See Removal Detail
See Installation Detail
12
-
Turbocharger retaining nuts
See Installation Detail
13
-
Turbocharger support bracket retaining bolt
See Installation Detail
14
-
Turbocharger
See Removal Detail
See Installation Detail

8. To install, reverse the removal procedure.

  1. Initialize the door window motors. For additional information, refer to Section  501-11 Glass, Frames and Mechanisms.

Removal Details

Item 2 : Catalytic converter heat shield

  1. Lower the vehicle.

Item 3 : Turbocharger outlet pipe

  1. Rotate the turbocharger outlet pipe and remove.

Item 11 : Catalytic converter to turbocharger clamp

  1. Make a note of the position of the catalytic converter clamp.

Item 14 : Turbocharger

  1. Remove the turbocharger retaining studs.

Installation Details

Item 14 : Turbocharger
  1. Install the turbocharger retaining studs.

Item 13 : Turbocharger support bracket retaining bolt

  1. Do not tighten the turbocharger support bracket retaining bolt at this stage.

Item 12 : Turbocharger retaining nuts

  1. Tighten the turbocharger support bracket retaining bolt.

Item 11 : Catalytic converter to turbocharger clamp
  1. Install the catalytic converter clamp in the same position as when removed.

Item 1 : Catalytic converter heat shield lower retaining bolts

  1. Raise the vehicle.

Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (110 PS), VIN Plate Emission Level Code: K > < Turbocharger - 1.6L Duratorq-TDCi (DV) Diesel (90 PS)