Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position the turbocharger on the turbocharger pedestal.
- Place the turbocharger onto the mounting bracket. Make sure the exhaust inlet pipe is correctly aligned to the turbocharger. If it is not, loosen the mounting bracket and reposition the turbocharger and mounting bracket for correct alignment. Complete the turbocharger installation.

NOTE: Install new O-rings and apply clean engine oil.

Fig 1: Installing Turbocharger Drain Tube

Courtesy of FORD MOTOR CO.

Position the turbocharger and install the turbocharger drain tube.

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

Fig 2: Installing Turbocharger And Rear Mounting Bolt

Courtesy of FORD MOTOR CO.

Install the turbocharger and the rear mounting bolt.

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

Fig 3: Installing Turbocharger Front Mounting Bolts

Courtesy of FORD MOTOR CO.

Install the turbocharger front mounting bolts.
Install the turbocharger inlet marmon clamp.

Fig 4: Installing Turbocharger Inlet Marmon Clamp
Courtesy of FORD MOTOR CO.
Position the clamp and tighten to specification.

Fig 5: Tightening Clamp
Courtesy of FORD MOTOR CO.
Make sure the exhaust inlet pipe is correctly aligned to the exhaust manifolds. Using hand tools, alternately tighten the nuts to draw the pipe to the exhaust manifold. There should be an equal gap spacing between the pipe flange and the exhaust manifold flange at the top and bottom bolts.

Fig 6: Tightening Nuts To Draw Pipe To Exhaust Manifold
Courtesy of FORD MOTOR CO.

NOTE: LH side shown, RH side similar.

Fig 7: Tightening Exhaust Inlet Pipe-To-Exhaust Manifold Nuts

Courtesy of FORD MOTOR CO.

Alternately tighten the exhaust inlet pipe-to-exhaust manifold nuts to specification.
Install the turbocharger exhaust marmon clamp.

Fig 8: Installing Turbocharger Exhaust Marmon Clamp
Courtesy of FORD MOTOR CO.
Position the wire retainer and install the bolt.

Fig 9: Installing Wire Retainer Bolt
Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring and apply clean engine oil.

Install the oil supply tube.
- Position the locking bracket and install the bolt.
  
  Fig 10: Installing Oil Supply Tube Locking Bracket Bolt
  Courtesy of FORD MOTOR CO.
Prelubricate the oil inlet hole of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearing with oil.
Position the oil feed tube and install the bolts.
- Install a new gasket.
  
  Fig 11: Installing Oil Feed Tube Bolts
  Courtesy of FORD MOTOR CO.
Connect the turbocharger variable vane hydraulic control valve electrical connector.

Fig 12: Locating Turbocharger Variable Vane Hydraulic Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Position the wiring harness and connect the push pins.

Fig 13: Connecting Wiring Harness Push Pins
Courtesy of FORD MOTOR CO.
Install the push pins.

Fig 14: Installing Push Pins
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 pipe to prevent the pipe from blowing off.

Fig 15: Turbocharger-To-Charge Air Cooler Duct Clamp - With Torque Specification

Courtesy of FORD MOTOR CO.

Connect the charge air cooler inlet pipe.
Install the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .