7.3L Power Stroke Turbocharger Removal & Installation

How to Remove the Turbo on a 1999.5 - 2003 7.3L Power Stroke

Removing and installing a turbocharger on a late 1999 - 2003 Super Duty equipped with a 7.3L Power Stroke is relatively straight forward. In fact, it's easy in comparison to removing the turbo from an earlier 7.3L Power Stroke or the later 6.0L Power Stroke. With the turbocharger removed, inspect the up-pipe collector gaskets; they should be replaced if the collector moves excessively or there are signs that the collector donut gaskets are leaking.

Note - These procedures are relevant for LATE 1999 - 2003 Super Duty pickups with a GTP38 turbocharger. See related links in sidebar for 1994 - EARLY 1999 turbocharger removal/installation procedures.

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

• Position the turbocharger forward until it releases from the exhaust "Y" collector, then guide the EBPV linkage off of the backpressure valve swing arm as you lift the turbocharger upwards slightly.

• Carefully remove the turbocharger from the vehicle. The turbocharger is heavy and can be awkward to guide out of the engine - be patient and maneuver cautiously.

7.3L Power Stroke GTP38 Turbocharger Installation

Replacing turbo pedestal o-rings

• Replace the pair of turbocharger pedestal o-rings - these are not to be reused. Lightly lubricate them with clean engine oil prior to installation.

• Install a new Marman clamp on the exhaust "Y" collector loosely as not to interfere with turbocharger re-installation.

• It is recommended to replace the EBPV linkage clip with a new one, as supplied in the turbocharger reinstall kit, before reinstalling the turbo.

• Reinstall the turbocharger onto the turbo pedestal then line up and reinstall the EBPV linkage. Also ensure that the indentation on the turbocharger turbine is properly aligned with the "Y" collector alignment pin, then install the turbocharger to pedestal bolts hand tight. Ensure that the pedestal o-rings have not been dislodged by mistake

• Torque turbocharger pedestal bolts to 18 ft-lbs.

Reinstalling turbocharger

• Align, tighten, then torque the exhaust collector to turbine Marman clamp to 60 in-lbs.

• Reinstall the exhaust downpipe, torque Marman clamp at turbine outlet to to 60 in-lbs.

• Remove any rags in the intake manifold openings, then reinstall the intake manifold plenum using a new o-ring seal between the plenum and turbocharger compressor outlet. Lightly lube the new o-ring with clean engine oil.

• Tighten intake plenum to turbocharger clamp - snug, do not over-tighten.

• Tighten intake manifold to intake plenum boots.

• Reinstall intercooler tubes to the intake plenum, tighten all clamps.

• Reinstall remaining sensors, intake tubing, and wastegate actuator lines.

• Reconnect negative battery cables, start engine, and test for leaks and/or additional problems.