Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, and 2004 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.

Fig 1: Installing Turbocharger

Courtesy of FORD MOTOR CO.

Position the turbocharger in the vehicle. Install the turbocharger drain tube and turbocharger.

NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the bolt threads prior to installation.

Fig 2: Identifying Tightening Torque Of LH Turbocharger Mounting Bolts

Courtesy of FORD MOTOR CO.

Install the LH turbocharger mounting bolts.

NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the bolt threads prior to installation.

Fig 3: Identifying Tightening Torque Of RH Turbocharger Mounting Bolts

Courtesy of FORD MOTOR CO.

Install the RH turbocharger mounting bolts.
Prelubricate 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.

NOTE: Use a new gasket when installing the oil feed tube.

Fig 4: Identifying Tightening Torque Of Turbocharger Oil Feed Tube Gasket Bolts

Courtesy of FORD MOTOR CO.

Install the turbocharger oil feed tube, gasket and bolts.
Connect the VGT actuator electrical connector and retaining clip.

Fig 5: Connecting VGT Actuator Electrical Connector And Retaining Clip
Courtesy of FORD MOTOR CO.
Position the turbocharger adapter pipe and install the turbocharger inlet clamp.

Fig 6: Identifying Tightening Torque Of Turbocharger Inlet Clamp Bolt
Courtesy of FORD MOTOR CO.
Install the EGR cooler clamp.

Fig 7: Identifying Tightening Torque Of EGR Cooler Clamp Bolt
Courtesy of FORD MOTOR CO.

NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the bolt threads prior to installation.

Fig 8: Identifying Tightening Torque Of Turbocharger Adapter Pipe RH Bolt

Courtesy of FORD MOTOR CO.

Install the RH bolts for the turbocharger adapter pipe.

NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the bolt threads prior to installation.

Fig 9: Identifying Tightening Torque Of Turbocharger Adapter Pipe LH Bolt

Courtesy of FORD MOTOR CO.

Install the LH bolts for the turbocharger adapter pipe.
Position back the turbocharger exhaust pipe. Install the turbocharger exhaust clamp.

Fig 10: Identifying Tightening Torque Of Turbocharger Exhaust Clamp Bolt
Courtesy of FORD MOTOR CO.
Tighten the retaining nuts at the exhaust clamp.

Fig 11: Identifying Tightening Torque Of Exhaust Clamp Nuts
Courtesy of FORD MOTOR CO.
Tighten the turbocharger outlet clamp.

Fig 12: Identifying Tightening Torque Of Turbocharger Outlet Clamp Bolt
Courtesy of FORD MOTOR CO.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler tube to prevent the tube from blowing off.

Fig 13: Positioning Charge Air Cooler Tube And Bracket

Courtesy of FORD MOTOR CO.

Position the charge air cooler tube and bracket. Install the retaining nuts.
Install the bolts for the charge air cooler tube and oil fill tube.

Fig 14: Installing Bolts For Charge Air Cooler Tube And Oil Fill Tube
Courtesy of FORD MOTOR CO.
Install the conduit and bolts.
- Install the wiring harness into the conduit and connect the push pins.
- Install the bolts.
- Connect the locking tab.
Fig 15: Installing Conduit And Bolts
Courtesy of FORD MOTOR CO.
Connect the electrical connector push pin. Position back the ground wire and install the bolt.

Fig 16: Installing Electrical Connector And Ground Wire
Courtesy of FORD MOTOR CO.
Install the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .