Turbocharger Assembly

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: Do not apply anti-seize lubricant to the turbocharger vanes and posts as it may prevent proper operation of the turbocharger vanes.

Apply a light coating of anti-seize lubricant to the turbine housing center section.
- Remove all excessive lubricant with a clean shop towel.
  
  Fig 1: Locating Turbine Housing Center Section
  Courtesy of FORD MOTOR CO.
Apply a light coating of anti-seize lubricant to the turbine housing center section and pilot diameters.

Fig 2: Locating Turbine Housing Center Section And Pilot Diameters
Courtesy of FORD MOTOR CO.
Apply a light coating of anti-seize lubricant to both sides of the unison ring.
- Remove all excessive lubricant from the unison ring grooves.
  
  Fig 3: Locating Unison Ring Grooves
  Courtesy of FORD MOTOR CO.
Install the turbocharger vanes into the turbine housing.

Fig 4: Locating Turbocharger Vanes
Courtesy of FORD MOTOR CO.
Position the unison ring onto the turbocharger vanes, aligning it with the mark on the side of the turbine housing.
- Verify free movement of the turbocharger vanes and unison ring.
  
  Fig 5: Locating Mark On Side Of Turbine Housing
  Courtesy of FORD MOTOR CO.

NOTE: Position the V-band clamp on the turbine housing prior to assembly of the turbocharger.

Fig 6: Locating V-Band Clamp On Turbine Housing

Courtesy of FORD MOTOR CO.

Lower the center housing section onto the turbine housing, aligning the unison ring crank first, then the housing dowel.
Align the V-band clamp with the paint mark. Install the locknut for the V-band clamp. Apply anti-seize lubricant to the threads of the V-band clamp. Tighten the nut in 5 stages.
- Stage 1: Tighten to 18 Nm (159 lb-in).
- Stage 2: Loosen the nut.
- Stage 3: Tighten to 5 Nm (44 lb-in).
- Stage 4: Tap on the V-band clamp with a rubber mallet to seat the clamp.
- Stage 5: Tighten to 17 Nm (150 lb-in).
  
  Fig 7: Locating V-Band Clamp Retaining Nut
  Courtesy of FORD MOTOR CO.
Install the turbocharger heat shield and 3 bolts.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 8: Locating Bolts And Turbocharger Heat Shield
  Courtesy of FORD MOTOR CO.

NOTE: Do not spray brake parts cleaner directly into the turbocharger as it may remove the previously applied lubricants.

Remove the duct tape or covers from the turbocharger.
- Remove any tape residue with a shop towel dampened with brake parts cleaner.
Verify that the engine has the updated turbocharger oil drain tube.
- Measure the turbocharger drain tube diameter. An updated tube will measure approximately 22.225 mm (0.875 in). The old style drain tube will measure approximately 19.05 mm (0.750 in). Replace the turbocharger drain tube if it is the old style tube.
  
  Fig 9: Locating Turbocharger Drain Tube Diameter Measuring Area
  Courtesy of FORD MOTOR CO.
Install the turbocharger. For additional information, refer to Installation .