Turbocharger Inlet Y-Pipe: 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: Only tighten the turbocharger inlet Y-pipe fasteners with hand tools.

NOTE: When installing the turbocharger inlet Y-pipe into, do not bend or twist the flex bellows.

NOTE: Do not tighten the nuts at this time.

NOTE: Apply anti-seize lubricant to the turbocharger inlet Y-pipe bolts.

Fig 1: Locating Turbocharger Pipe Nuts

Courtesy of FORD MOTOR CO.

If the turbocharger inlet Y-pipe was separated, install the gasket and loosely install the bolts and nuts.
Position the turbocharger inlet Y-pipe into the vehicle.

NOTE: Do not tighten the clamp at this time.

Fig 2: Identifying Turbocharger Inlet Clamp

Courtesy of FORD MOTOR CO.

Position the turbocharger inlet clamp.

NOTE: Do not tighten the clamp at this time.

Fig 3: Identifying EGR Cooler Clamp Bolt

Courtesy of FORD MOTOR CO.

Install the metal gasket on the EGR cooler and align the turbocharger inlet Y-pipe to the EGR cooler. Position the clamp.

NOTE: LH side shown, RH side similar.

NOTE: Do not tighten the turbocharger inlet Y-pipe-to-exhaust manifold bolts.

Fig 4: Identifying Turbocharger Adapter Pipe Bolts

Courtesy of FORD MOTOR CO.

Apply anti-seize lubricant to the turbocharger inlet Y-pipe bolts, than install the bolts and nuts.
Tighten the turbocharger inlet clamp.

Fig 5: Tightening Turbocharger Inlet Clamp
Courtesy of FORD MOTOR CO.
Tighten the EGR cooler clamp.

Fig 6: Tightening EGR Cooler Clamp
Courtesy of FORD MOTOR CO.
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.

Fig 7: Identifying Turbocharger Inlet Y-Pipe
Courtesy of FORD MOTOR CO.

NOTE: LH side shown, RH side similar.

Fig 8: Tightening Turbocharger Inlet Y-Pipe-To-Exhaust Manifold Bolts

Courtesy of FORD MOTOR CO.

Alternately tighten the turbocharger inlet Y-pipe-to-exhaust manifold bolts.
If loosened, tighten the turbocharger inlet Y-pipe nuts at the RH to LH joint.

Fig 9: Tightening Turbocharger Inlet Y-Pipe Nuts At RH To LH Joint
Courtesy of FORD MOTOR CO.
Check the systems for leaks.
Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION . .