Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 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: Locating 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.

Install the turbocharger and the rear mounting bolt.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 2: Locating Rear Mounting Bolt
  Courtesy of FORD MOTOR CO.

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

Install the turbocharger front mounting bolts.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 3: Locating Turbocharger Front Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the turbocharger inlet marmon clamp.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 4: Locating Turbocharger Inlet Marmon Clamp
  Courtesy of FORD MOTOR CO.
Position the clamp and tighten to specification.
- Tighten to 6 Nm (53 lb-in).
  
  Fig 5: Locating EGR Cooler V-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: Locating Exhaust Inlet Pipe
Courtesy of FORD MOTOR CO.

NOTE: LH side shown, RH side similar.

Alternately tighten the exhaust inlet pipe-to-exhaust manifold nuts to specification.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 7: Identifying Adapter Pipe Bolts
  Courtesy of FORD MOTOR CO.
Install the turbocharger exhaust marmon clamp.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 8: Locating Turbocharger Exhaust Marmon Clamp
  Courtesy of FORD MOTOR CO.
Position the wire retainer and install the bolt.

Fig 9: Locating 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.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 10: Locating 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.
Install a new oil feed tube gasket, the oil feed tube and the 2 bolts.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 11: Locating 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: Locating Push Pins
Courtesy of FORD MOTOR CO.
Install the push pins.

Fig 14: Locating 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.

Connect the CAC inlet pipe.
- Tighten to 12 Nm (9 lb-ft).
  
  Fig 15: Locating CAC Inlet Pipe
  Courtesy of FORD MOTOR CO.
Install the turbocharger intake tube. For additional information, refer to TURBOCHARGER INTAKE TUBE .