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Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Install new drain tube O-ring seals and apply clean engine oil.
    NOTE: Position the turbocharger outlet flange into the outlet hose as the turbocharger is positioned on the engine.
  1. Position the turbocharger in the vehicle. Install the turbocharger drain tube and turbocharger.
    2. Fig 1: Locating Turbocharger Drain Tube
    G03888091Courtesy of FORD MOTOR CO.
    NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.
  2. Install the 2 LH turbocharger mounting bolts.
    • Tighten to 31 Nm (23 lb-ft).
    3. Fig 2: LH Turbocharger Mounting Bolt
    GF0011982Courtesy of FORD MOTOR CO.
    NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.
  3. Install the RH turbocharger mounting bolt.
    • Tighten to 31 Nm (23 lb-ft).
    4. Fig 3: RH Turbocharger Mounting Bolt
    GF0011981Courtesy of FORD MOTOR CO.
  4. Pre-lubricate the oil inlet hole of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearings with oil.
    5. NOTE: Use a new gasket and O-ring seal when installing the oil feed tube.
  5. Position back the turbocharger oil feed tube and install a new gasket and the 2 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    6. Fig 4: Turbocharger Oil Feed Tube Bolts
    GF0011980Courtesy of FORD MOTOR CO.
  6. Install the bolt for the turbocharger oil feed tube.
    • Tighten to 10 Nm (89 lb-in).
    7. Fig 5: Locating Turbocharger Oil Supply Tube Bolt
    GF0005945Courtesy of FORD MOTOR CO.
  7. Connect the turbocharger variable vane hydraulic control valve electrical connector and install the wiring harness into the retaining clip.
    8. Fig 6: Variable Geometry Turbocharger (VGT) Actuator Electrical Connector
    GF0011979Courtesy of FORD MOTOR CO.
  8. Position the turbocharger adapter pipe and install the turbocharger inlet clamp.
    • Tighten to 12 Nm (106 lb-in).
    9. Fig 7: Identifying Turbocharger Inlet Clamp
    G03888086Courtesy of FORD MOTOR CO.
  9. Install the EGR cooler clamp.
    • Tighten to 6 Nm (53 lb-in).
    10. Fig 8: Identifying EGR Cooler Clamp Bolt
    G03889745Courtesy of FORD MOTOR CO.
    NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.
  10. Install the 2 RH bolts and 2 new nuts for the exhaust tube-to-exhaust manifold flange.
    • Tighten to 27 Nm (20 lb-ft).
    11. Fig 9: Identifying Turbocharger Adapter Pipe RH Bolts
    G03887224Courtesy of FORD MOTOR CO.
    NOTE: Apply anti-seize lubricant to the bolt threads prior to installation.
  11. Install the 2 LH bolts and 2 new nuts for the exhaust tube-to-exhaust manifold flange.
    • Tighten to 27 Nm (20 lb-ft).
    12. Fig 10: Identifying Turbocharger Adapter Pipe Bolts
    G03887218Courtesy of FORD MOTOR CO.
  12. Position the exhaust downpipe. Install the turbocharger exhaust clamp.
    • Tighten to 10 Nm (89 lb-in).
    13. Fig 11: Turbocharger Outlet Clamp
    GF0011978Courtesy of FORD MOTOR CO.
  13. Install the 2 new retaining nuts at the exhaust clamp.
    • Tighten to 47 Nm (35 lb-ft).
    14. Fig 12: Locating Nuts On Exhaust Downpipe
    GF0044559Courtesy of FORD MOTOR CO.
    NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC tube to prevent the tube from blowing off.
  14. Position the CAC tube and bracket and install the 2 retaining nuts.
    15. Fig 13: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket
    G03887099Courtesy of FORD MOTOR CO.
  15. Install the 3 bolts for the CAC tube and oil fill tube.
    16. Fig 14: Locating CAC Tube And Oil Fill Tube Bolts
    G03887097Courtesy of FORD MOTOR CO.
  16. Install the conduit and 3 bolts.
    • Install the wiring harness into the conduit and connect the pushpins.
    • Install the 3 bolts.
    • Connect the locking tab.
    17. Fig 15: Identifying Wire Harness Pin-Type Retainers
    G03888078Courtesy of FORD MOTOR CO.
  17. Connect the electrical connector pushpin. Position the ground wire and install the bolt.
    18. Fig 16: Identifying Ground Wire Bolt & Electrical Connector
    G03887094Courtesy of FORD MOTOR CO.
  18. Tighten the turbocharger outlet clamp.
    • Tighten to 12 Nm (106 lb-in).
    19. Fig 17: Locating Turbocharger Outlet Clamp
    GF0044604Courtesy of FORD MOTOR CO.
  19. Install the turbocharger intake tube. For additional information, refer to Turbocharger Intake Tube .
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