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Turbocharger Inlet Y-Pipe: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 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.
CAUTION: Only tighten the turbocharger inlet Y-pipe fasteners with hand tools or damage to the turbocharger inlet pipe may occur.
CAUTION: When installing the turbocharger inlet Y-pipe into the vehicle, do not bend or twist the flex bellows or damage to the flex bellows may occur.
    NOTE: Do not tighten the nuts at this time.
    NOTE: Apply anti-seize lubricant to the turbocharger inlet Y-pipe bolts.
  1. If the turbocharger inlet Y-pipe was separated, install the gasket and loosely install the bolts and new nuts.
    2. Fig 1: Locating Turbocharger Pipe Nuts
    G03889747Courtesy of FORD MOTOR CO.
  2. Position the turbocharger inlet Y-pipe into the vehicle.
    3. NOTE: Do not tighten the clamp at this time.
  3. Position the turbocharger-to-turbocharger inlet Y-pipe clamp.
    4. Fig 2: Identifying Turbocharger Inlet Clamp
    G03888086Courtesy of FORD MOTOR CO.
    NOTE: Do not tighten the clamp at this time.
  4. Install the new metal gasket on the EGR cooler and align the turbocharger inlet Y-pipe to the EGR cooler. Position the clamp.
    5. Fig 3: Identifying EGR Cooler Clamp Bolt
    G03889745Courtesy of FORD MOTOR CO.
    NOTE: LH side shown, RH side similar.
    NOTE: Do not tighten the turbocharger inlet Y-pipe-to-exhaust manifold bolts at this time.
  5. Apply anti-seize lubricant to the turbocharger inlet Y-pipe-to-exhaust manifold bolts, then install the bolts and new nuts.
    6. Fig 4: Identifying Turbocharger Adapter Pipe Bolts
    G03887218Courtesy of FORD MOTOR CO.
  6. Tighten the turbocharger-to-turbocharger inlet Y-pipe clamp.
    • Tighten to 12 Nm (9 lb-ft).
    7. Fig 5: Identifying Turbocharger Inlet Clamp
    G03888086Courtesy of FORD MOTOR CO.
  7. Tighten the turbocharger inlet Y-pipe-to-EGR cooler clamp.
    • Tighten to 6 Nm (53 lb-in).
    8. Fig 6: Identifying EGR Cooler Clamp Bolt
    G03889745Courtesy of FORD MOTOR CO.
  8. Make sure the turbocharger inlet Y-pipe is correctly aligned to the exhaust manifolds. Using hand tools, alternately tighten the nuts to draw the turbocharger inlet Y-pipe to the exhaust manifold. There should be an equal gap spacing between the turbocharger inlet Y-pipe and the exhaust manifold flange at the top and bottom bolts.
    9. Fig 7: Aligning Exhaust Inlet Pipe
    GF0005952Courtesy of FORD MOTOR CO.
    NOTE: LH side shown, RH side similar.
  9. Alternately tighten the turbocharger inlet Y-pipe-to-exhaust manifold bolts.
    • Tighten to 27 Nm (20 lb-ft).
    10. Fig 8: Identifying Turbocharger Adapter Pipe Bolts
    G03887218Courtesy of FORD MOTOR CO.
  10. If loosened, tighten the turbocharger inlet Y-pipe nuts at the RH to LH joint.
    • Tighten to 27 Nm (20 lb-ft).
    11. Fig 9: Locating Turbocharger Pipe Nuts
    G03889747Courtesy of FORD MOTOR CO.
  11. Check the systems for leaks.
  12. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
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