Ford Falcon. Manual — part 177

303-04b-18

Fuel Charging and Controls — Turbocharger

303-04b-18

REMOVAL AND INSTALLATION (Continued)

17. Remove the turbocharger from the exhaust

2. Refit the dump-pipe to the turbocharger.

manifold.

1. Install a new dump-pipe gasket.

1. Remove and discard the two remaining nuts.

2. Use new stainless steel studs if necessary.

2. Inspect the threads on the studs. Replace if

3. Use new copper coated nuts.

damaged.

4. Torque nuts to specifications.

Installation

3. Install the exhaust manifold, turbocharger and

All vehicles

dump-pipe assembly.

NOTE: Install a new exhaust manifold gasket.

1. Install a new manifold gasket.

NOTE: Install a new dump-pipe gasket.

2. First, fit the bottom two turbocharger mounting

studs into the H-Brace holes, then lower the

NOTE: Install a new oil return line gasket.

manifold onto the head.

NOTE: Install new oil supply line sealing washers

(x2).

NOTE: Install new coolant supply line gaskets (x2).

NOTE: Install new coolant return line gaskets (x2).

1. Refit the turbocharger onto the exhaust manifold.

1. Use new stainless steel studs if necessary

2. Fit the upper two nuts only at this stage.

3. Use new copper coated nuts.

4. Torque nuts to specifications.

NOTE: There is no gasket between the

exhaust manifold and turbocharger.

3. Install the manifold mounting bolts, leaving

out the four bolts that mount the heat shields

and the one bolt that mounts the pencil brace.

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303-04b-19

Fuel Charging and Controls — Turbocharger

303-04b-19

REMOVAL AND INSTALLATION (Continued)

4. Fit the two remaining copper nuts to the

7. Connect the oil return tube to the turbocharger.

turbocharger mounting studs.

1. Install a new oil return line gasket.

5. Fit the pencil brace to the dump-pipe and

2. Use Loctite Thread Sealer or equivalent on

exhaust manifold

bolts.

6. Torque all the bolts to specification.

4. Install the heat shielding to the turbocharger.

1. Fit the remaining exhaust manifold bolts with

the heatshields.

2. Fit one of the heat shield retaining screws into

the dump-pipe.

3. Fit the other heat shield retaining screw into

the manifold.

4. Torque all the hardware to specification.

Item

Description

1

Oil supply line

2

Oil return line

8. Connect the coolant outlet tube to the

turbocharger.

1. Install a new coolant outlet line sealing

washers.

2. Use Loctite Thread Sealer or equivalent on

5. Reconnect the HEGO sensor wiring.

bolts.

6. Connect the exhaust catalyst to dump-pipe.

1. Use new studs if necessary.

2. Use new catalyst pipe nuts.

3. Torque nuts to specifications.

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303-04b-20

Fuel Charging and Controls — Turbocharger

303-04b-20

REMOVAL AND INSTALLATION (Continued)

9. Connect the coolant inlet lines to the

11. Install the fresh air inlet duct to the turbocharger.

turbocharger.

1. Install the pipe duct.

1. Install a new coolant inlet line sealing

2. Tighten the hose clamps to specification.

washers.

2. Use Loctite Thread Sealer or equivalent on

bolts.

12. Connect the battery ground cable. For additional

information, refer to Section 414-01.

13. Start engine and check all connections for

10. Connect the charge air cooler intake pipe.

oil/water/air leaks.

CAUTION: Make sure that the inside of

Boost Pressure Sensor

the charge air cooler intake pipe is clean and

free from any residue as this will reduce the

Removal

installation grip of the pipe to the charge air

1. Disconnect the wire harness from the BPS

cooler. Failure to follow this instruction may

connector.

result in engine damage.

2. Undo the retaining bolt.

1. Install the pipe to the turbocharger.

3. Gently pull the sensor out vertically from the

2. Refit the two hose clamps and tighten to

aluminium duct.

specification.

Installation
1. Push the new BPS into the aluminium duct.
2. Refit the retaining bolt and tighten.

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303-04b-21

Fuel Charging and Controls — Turbocharger

303-04b-21

REMOVAL AND INSTALLATION (Continued)

3. Reconnect the harness to the BPS.

5. Reconnect the harness to the WCS.

Charge Air Cooler (Intercooler)

Removal
1. Remove bumper and grill, Refer Section 501-19

of this workshop manual.

2. Remove horns, Refer Section 413-06 of this

workshop manual.

3. Remove RH headlamp, Refer Section 417-01 of

this workshop manual

4. Undo the clamps and disconnect the tube that

runs from the top of the intercooler to the under

headlamp duct.

5. Undo the clamps and disconnect the tube that

runs from the turbocharger to the intercooler.

Wastegate Control Solenoid (WCS)

6. Remove the nuts holding the intercooler to the

passenger side mounting bracket

Removal

7. Remove the nuts holding the driver’s side

1. Disconnect the wire harness from the WCS

mounting bracket to the crossmember and

connector.

remove the bracket and the intercooler together.

2. Disconnect the hose that runs from the

8. Remove the nuts holding the RH bracket to the

turbocharger compressor to the WCS.

intercooler.

3. Disconnect the hose that runs from the WCS to

9. Remove the cushion connectors from the

the wastegate actuator on the turbocharger.

intercooler ends.

4. Undo the retaining bolt.

10. Remove the wiring harness from the under

5. Withdraw the Wastegate Control Solenoid.

headlamp duct.

11. Undo the bolt retaining the earth wire and under

headlamp duct to the body.

12. Remove the duct from under the battery tray by

twisting and removing at the same time.

Item

Description

1

Hose WCS to turbo compressor

2

WCS electrical connection

3

Hose turbocharger actuator to WCS

4

Wastgate control solenoid (WCS)

Item

Description

1

Cool air to intake manifold

Installation

2

Cool air duct and BPS

1. Fit the Wastegate Control Solenoid into position.

3

TURBO to intercooler

2. Refit the retaining bolt and tighten.

4

Cool air hose from intercooler

3. Connect the hose that runs from the WCS to the

wastegate actuator on the turbocharger.

5

Intercooler

4. Connect the hose that runs from the turbocharger

6

Intercooler mounting bracket

compressor to the WCS.

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