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7.3L Power Stroke Turbocharger Removal Installation

Time:2018-01-12 03:59Turbochargers information Click:

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Garrett GTP38 Turbocharger Reinstallation Parts List

Part Description

Part Numbers

Notes

GTP38 turbocharger reinstall kit

Ford F81Z-6N653-BA
International 1831658C91

Includes all o-rings, turbocharger hardware

Up-pipe collector to turbine inlet clamp

Ford F81Z-8287-EA

Can be reused, replace if damaged/worn

Turbine outlet to downpipe clamp

Ford XC3Z-5A231-AA

Can be reused, replace if damaged/worn

Compressor outlet to intake "spider" plenum clamp

Ford 1831214C1

Can be reused, replace if damaged/worn

7.3L Power Stroke GTP38 Turbocharger Removal

Click any thumbnail to view high resolution fullsize image w/ addition details (where applicable)

Intercooler tube disconnected

• Disconnect both negative battery cables.

• Loosen clamps and disconnect intercooler tubes from the intake "spider" plenum. You do not need to remove the intercooler tubes completely, although it does leave more room to work if they are removed.

Plenum closeup

• Remove air intake heater (AIH) wire leads (pair of lug connectors).

• Disconnect intake air temperature (IAT) sensor connector.

• Disconnect manifold absolute pressure (MAP) sensor supply line.

• Disconnect wastegate pressure lines from wastegate solenoid and intake plenum.

• Remove wastegate solenoid from intake plenum (8 mm socket).

Wastegate actuator closeup

• Disconnect wastegate pressure line from wastegate actuator mounted near the rear of the turbocharger on the compressor side.

• Remove intake tubing between air filter box and turbocharger inlet.

All sensors and lines removed from plenum

• The intake plenum should have no wires, hoses, or connections attached to it at this point.

• Loosen the intake boots at the outlets of the intake plenum that feed into the intake manifolds at each bank of the engine.

Plenum to turbocharger clamp

• Generously loosen the Marman clamp connecting the intake plenum to the turbocharger compressor outlet.

• Loosen the clamps attaching the intake manifold boots to the intake plenum on each bank.

Removing intake plenum

• Pull the intake plenum outwards to break the seal between it and the turbocharger, then pull the plenum upwards to remove from the engine. There is an o-ring seal between the plenum and turbocharger - discard it, this does not get reused.

• Cover the now exposed intake manifold openings on each bank with clean rags to keep debris out.

Removing exhaust downpipe

• Generously loosen the Marman clamp attaching the exhaust downpipe to the turbocharger turbine outlet. Disconnect the downpipe from the turbocharger and allow it to hang freely.

• If replacing up-pipe gaskets, separate the downpipe from the exhaust system, then completely remove it from the vehicle. Separating the downpipe from the exhaust system may prove difficult - penetrating oil, patience, and a dead blow hammer will make matters easier.

Disconnecting EBPV linkage from turbo

• Disconnect the exhaust backpressure valve (EBPV) linkage from the turbocharger. To do so, locate the small sliding clip on the bottom of the link. Slide the clip towards the driver's side to disconnect. The linkage does not get completely removed at this point.

Removing exhaust up pipe collector clamp

• Locate and remove the Marman clamp connecting the exhaust "Y" collector to the turbocharger turbine inlet. Once the clamp is loosened, you will need to pry the clamp off with a screwdriver - these have a tendency to stick.

Turbocharger to pedestal mounting bolts

• Remove the two turbocharger mounting bolts located between the compressor and turbine housings.

Removing turbocharger

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