Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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 Drain Tube O-Ring Seals

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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: Installing LH Turbocharger Mounting Bolts

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Install the LH turbocharger mounting bolts.

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

Fig 3: Installing RH Turbocharger Mounting Bolt

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Install the RH turbocharger mounting bolt.
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: Installing Oil Feed Tube

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Position back the turbocharger oil feed tube. Install a new gasket and the bolts.
Connect the VGT actuator electrical connector and retaining clip.

Fig 5: Connecting VGT Actuator Electrical Connector
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Position the turbocharger adapter pipe and install the turbocharger inlet clamp.

Fig 6: Installing Turbocharger Inlet Clamp
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Install the EGR cooler clamp.

Fig 7: Installing EGR Cooler Clamp
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NOTE: Apply High Temperature Nickel Anti-Seize Lubricant to the bolt threads prior to installation.

Fig 8: Installing RH Bolts For Turbocharger Adapter

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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: Installing LH Bolts For Turbocharger Adapter Pipe

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

Fig 10: Installing Turbocharger Exhaust Clamp
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Tighten the retaining nuts at the exhaust clamp.

Fig 11: Tightening Retaining Nuts At Exhaust Clamp
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Tighten the turbocharger outlet clamp.

Fig 12: Tightening Turbocharger Outlet Clamp
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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: Locating Bracket Retaining Nuts

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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: Locating CAC Tube And Oil Fill Tube Bolts
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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
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Connect the electrical connector push pin. Position back the ground wire and install the bolt.

Fig 16: Connecting Electrical Connector Push Pin
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Install the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .