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Turbocharger Cleaning Procedure
Remove the turbocharger for inspection following Workshop Manual, Section 303-04D: Fuel Charging and Controls.
Inspect compressor and turbine wheel fins for damage. Replace the turbocharger if fins are damaged. If fins are damaged, inspect the air intake system for damage allowing dirt or contamination to bypass the air filter.
Perform a turbocharger Bearing Clearance Check following Workshop Manual, Section 303-04D. Replace turbocharger if bearing fails the check.
Cover the inlet and outlet of the turbocharger compressor housing with duct tape or covers. Clean the oil supply line mounting surface and cover with duct tape or covers. Place a clean paper towel or cover into the turbocharger oil drain passage.
Using a paint pen, mark the location and direction of the v-clamp.
Using a paint pen, mark the location of the turbine housing at unison ring crank to make reassembly easier.
NOTE: DO NOT REMOVE TURBINE WHEEL/COMPRESSOR WHEEL ASSEMBLY OR COMPRESSOR HOUSING.
Remove the v-clamp retaining nut completely from clamp assembly. Move v-clamp from flanges so the turbocharger housings can be separated.
Separate the housings by using a hammer and brass drift.
Separate vanes and unison ring from turbine housing and center housing and check for coking from oil. If turbocharger is coked with carbon deposits from oil, the deposits will be wet and black and cover the complete inside of the turbo .
If the turbocharger is oil coked, continue with this TSB.
If the turbocharger is not oil coked, replace the turbocharger and do not continue with this TSB. This TSB is only for cleaning a turbo that is coked because of excess oil.
NOTE: DO NOT ATTEMPT TO CLEAN RUST OR CORROSION.
NOTE: IF THE REPLACEMENT TURBO DOES NOT COME WITH A VGT, TRANSFER THE VGT FROM THE TURBO BEING REPLACED.
Inspect the unison ring for cracks. Replace the turbocharger if the unison ring is cracked.
To clean the carbon deposits, wet the unison ring, vanes, and turbine housing and center housing unison ring and vane contact areas with Carburetor Tune-Up Cleaner.
NOTE: DO NOT CLEAN THE TURBINE WHEEL AND USE CAUTION WHEN CLEANING AROUND IT.
NOTE: A RAZOR BLADE IN A HOLDER MAY BE USED WHERE THERE IS SUFFICIENT ACCESS TO REMOVE THE BULK OF CARBON DEPOSITS.
NOTE: USE A DUST MASK WHEN CLEANING TURBO CHARGER SURFACES.
Finish cleaning the center housing, unison ring and vanes with a Scotch-Brite™ 2" (5 cm) abrasive disc 051131-07480, or equivalent (obtain locally). Ensure these areas are free of carbon :
Center housing unison ring hub
Center housing facing surface
Unison ring inner diameter
Unison ring outer diameter
Unison ring facing surfaces
Unison ring crank hole
Unison ring vane slots
Vanes - all contact points
Using scissors, cut the Scotch-Brite™ disc used in step 12 to match a 1" (2.5 cm) 3M™ ROLOC™ + Holder (61-5000-7982-9) .
NOTE: NOTE: THE DISC MUST BE MODIFIED TO THE 1" (2.5 cm) SIZE TO COMPLETE THE CLEANING EFFECTIVELY.
NOTE: NOTE: AVOID DAMAGING VANE PIVOT PINS DURING THE CLEANING PROCESS. PIN DAMAGE CAN CAUSE UNWANTED NOISE AND/OR IMPAIR TURBOCHARGER PERFORMANCE .
Finish cleaning the turbine housing using the modified disc. Remove the carbon deposits from all surfaces that contact moving parts, as well as the mating surfaces of the housing.
Apply a thin layer of engine oil to the turbine housing, center housing and unison ring. This procedure is to temporarily protect against surface corrosion. Applying anti-seize is not recommended.
Install the vanes into the turbine housing:
Index the unison ring onto the vanes.
Align the crank pin slot with the paint pen mark on the turbine housing.
Verify free movement of the vanes and unison ring.
Position v-clamp on the turbine housing in direction of paint pen mark.
Lower the center housing section onto the turbine housing, aligning the unison ring crank first, then the housing dowel.
Align the v-clamp with the paint marks. Coat the threads with Motorcraft® High Temperature Nickel Anti Seize.
Install the locknut using steps a through d:
Torque to 13 lb-ft/160 lb-in (18 N-m).
Loosen nut and torque to 4 lb-ft/50 lb-in (5 N-m).
Stand turbocharger on exhaust outlet then tap around the aluminum compressor housing with a rubber mallet to ensure complete seating.
Torque to 12 lb-ft/150 lb-in (17 N-m).
Remove the duct tape or covers from the turbocharger. Remove any tape residue with a paper towel dampened with brake cleaner.
NOTE: VGT SOLENOID REPLACEMENT IS NO LONGER NECESSARY. THE NEW OIL DRAIN TUBE WILL RESOLVE THE COKING ISSUE.
Reinstall the turbocharger with a new oil drain tube following Workshop Manual, Section 303-04D: Fuel Charging and Controls. The oil drain tube has been revised for greater turbocharger oil flow.
Remove the turbocharger for inspection following Workshop Manual, Section 303-04D: Fuel Charging and Controls.
Inspect compressor and turbine wheel fins for damage. Replace the turbocharger if fins are damaged. If fins are damaged, inspect the air intake system for damage allowing dirt or contamination to bypass the air filter.
Perform a turbocharger Bearing Clearance Check following Workshop Manual, Section 303-04D. Replace turbocharger if bearing fails the check.
Cover the inlet and outlet of the turbocharger compressor housing with duct tape or covers. Clean the oil supply line mounting surface and cover with duct tape or covers. Place a clean paper towel or cover into the turbocharger oil drain passage.
Using a paint pen, mark the location and direction of the v-clamp.
Using a paint pen, mark the location of the turbine housing at unison ring crank to make reassembly easier.
NOTE: DO NOT REMOVE TURBINE WHEEL/COMPRESSOR WHEEL ASSEMBLY OR COMPRESSOR HOUSING.
Remove the v-clamp retaining nut completely from clamp assembly. Move v-clamp from flanges so the turbocharger housings can be separated.
Separate the housings by using a hammer and brass drift.
Separate vanes and unison ring from turbine housing and center housing and check for coking from oil. If turbocharger is coked with carbon deposits from oil, the deposits will be wet and black and cover the complete inside of the turbo .
If the turbocharger is oil coked, continue with this TSB.
If the turbocharger is not oil coked, replace the turbocharger and do not continue with this TSB. This TSB is only for cleaning a turbo that is coked because of excess oil.
NOTE: DO NOT ATTEMPT TO CLEAN RUST OR CORROSION.
NOTE: IF THE REPLACEMENT TURBO DOES NOT COME WITH A VGT, TRANSFER THE VGT FROM THE TURBO BEING REPLACED.
Inspect the unison ring for cracks. Replace the turbocharger if the unison ring is cracked.
To clean the carbon deposits, wet the unison ring, vanes, and turbine housing and center housing unison ring and vane contact areas with Carburetor Tune-Up Cleaner.
NOTE: DO NOT CLEAN THE TURBINE WHEEL AND USE CAUTION WHEN CLEANING AROUND IT.
NOTE: A RAZOR BLADE IN A HOLDER MAY BE USED WHERE THERE IS SUFFICIENT ACCESS TO REMOVE THE BULK OF CARBON DEPOSITS.
NOTE: USE A DUST MASK WHEN CLEANING TURBO CHARGER SURFACES.
Finish cleaning the center housing, unison ring and vanes with a Scotch-Brite™ 2" (5 cm) abrasive disc 051131-07480, or equivalent (obtain locally). Ensure these areas are free of carbon :
Center housing unison ring hub
Center housing facing surface
Unison ring inner diameter
Unison ring outer diameter
Unison ring facing surfaces
Unison ring crank hole
Unison ring vane slots
Vanes - all contact points
Using scissors, cut the Scotch-Brite™ disc used in step 12 to match a 1" (2.5 cm) 3M™ ROLOC™ + Holder (61-5000-7982-9) .
NOTE: NOTE: THE DISC MUST BE MODIFIED TO THE 1" (2.5 cm) SIZE TO COMPLETE THE CLEANING EFFECTIVELY.
NOTE: NOTE: AVOID DAMAGING VANE PIVOT PINS DURING THE CLEANING PROCESS. PIN DAMAGE CAN CAUSE UNWANTED NOISE AND/OR IMPAIR TURBOCHARGER PERFORMANCE .
Finish cleaning the turbine housing using the modified disc. Remove the carbon deposits from all surfaces that contact moving parts, as well as the mating surfaces of the housing.
Apply a thin layer of engine oil to the turbine housing, center housing and unison ring. This procedure is to temporarily protect against surface corrosion. Applying anti-seize is not recommended.
Install the vanes into the turbine housing:
Index the unison ring onto the vanes.
Align the crank pin slot with the paint pen mark on the turbine housing.
Verify free movement of the vanes and unison ring.
Position v-clamp on the turbine housing in direction of paint pen mark.
Lower the center housing section onto the turbine housing, aligning the unison ring crank first, then the housing dowel.
Align the v-clamp with the paint marks. Coat the threads with Motorcraft® High Temperature Nickel Anti Seize.
Install the locknut using steps a through d:
Torque to 13 lb-ft/160 lb-in (18 N-m).
Loosen nut and torque to 4 lb-ft/50 lb-in (5 N-m).
Stand turbocharger on exhaust outlet then tap around the aluminum compressor housing with a rubber mallet to ensure complete seating.
Torque to 12 lb-ft/150 lb-in (17 N-m).
Remove the duct tape or covers from the turbocharger. Remove any tape residue with a paper towel dampened with brake cleaner.
NOTE: VGT SOLENOID REPLACEMENT IS NO LONGER NECESSARY. THE NEW OIL DRAIN TUBE WILL RESOLVE THE COKING ISSUE.
Reinstall the turbocharger with a new oil drain tube following Workshop Manual, Section 303-04D: Fuel Charging and Controls. The oil drain tube has been revised for greater turbocharger oil flow.
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