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303-05 Accessory Drive > < Turbocharger - Vehicles Built Up To: 07-2004, Vehicles With: Turbocharger Variable Vane Electric Actuator

Mondeo 2001 (10.2000-02.2007)

Fuel Charging and Controls - Turbocharger - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel - Turbocharger—Vehicles Built From: 07/2004, Vehicles With: Turbocharger Variable Vane Electric Actuator Mondeo 2001 (10/2000-02/2007)
Removal and Installation

Special Tool(s)

Release Tool, Belt Tensioner

303-676 (21-235)

Removal

  1. Disconnect the battery ground cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).

  1. Remove the engine cover.

  1. Remove the turbocharger heat shield.

  1. Disconnect the turbocharger variable vane electric actuator electrical connector.

  1. Remove the air cleaner outlet pipe.

  1. Disconnect the vacuum line from the brake vacuum pump and position it to one side.

  1. Remove the cowl grille heat shield.

  1. Remove the cowl grille brace bar.
  1. Raise and support the vehicle.
    For additional information, refer to: Lifting (100-02 Jacking and Lifting, Description and Operation).

  1. Remove the engine undershield.
    • Discard the clips.
  1. Remove the catalytic converter.
    For additional information, refer to: Catalytic Converter - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (309-00 Exhaust System, Removal and Installation).

  1. Remove the crankshaft pulley splash shield.

  1. Using the special tool, detach the accessory drive belt.

  1. Detach the generator and position it to one side (engine shown removed for clarity).

  1. Remove the charge air cooler intake pipe (engine shown removed for clarity).

  1. Remove the turbocharger oil return tube.
    • Discard the O-ring seal and gasket.

  1. Remove the turbocharger oil supply support bracket retaining bolt.

  1. NOTE:
    NOTE:The sealing washers cannot be removed from the turbocharger oil supply tube.
    Remove the turbocharger oil supply tube.

  1. Remove the exhaust gas recirculation (EGR) cooler retaining bracket.

  1. Detach the EGR cooler from the exhaust manifold and position it to one side.

  1. Remove the exhaust manifold retaining bolts and nuts.
    • Discard the bolts and nuts.
  1. Lower the vehicle.

  1. Detach the exhaust manifold heat shield from the exhaust manifold.
  1. Slide the turbocharger and exhaust manifold away from the engine and remove the exhaust manifold heat shield.

  1. CAUTION:
    CAUTION:Take care maneuvering the turbocharger and exhaust manifold passed the power steering line. Failure to follow this instruction may result in damage to the power steering line.
    Remove the turbocharger and exhaust manifold passed the brake booster.

Installation

CAUTION:
CAUTION:The turbocharger variable vane electric actuator must not be transferred between the old and new turbochargers. Failure to follow this instruction may result in incorrect calibration, emissions performance and engine operation.
CAUTION:
CAUTION:When installing the oil supply tube union to the turbocharger, check the routing of the oil supply tube and make sure that it is not touching the turbocharger.
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.
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.
NOTE:
NOTE:Remove and discard the blanking caps from the turbocharger and exhaust manifold assembly open ports.
NOTE:
NOTE:Install new exhaust manifold studs, bolts, nuts and all new gaskets, O-ring seals and sealing washers.
NOTE:
NOTE:Finger tighten the turbocharger electronic actuator bracket retaining bolts before tightening fully to allow correct alignment.
NOTE:
NOTE:Install new engine undershield clips.
  1. To install, reverse the removal procedure.
  1. Initialize the door window motors.
    For additional information, refer to: Door Window Motor Initialization (501-11 Glass, Frames and Mechanisms, General Procedures).

303-05 Accessory Drive > < Turbocharger - Vehicles Built Up To: 07-2004, Vehicles With: Turbocharger Variable Vane Electric Actuator