Disassembly And Assembly: Turbocharger: Assembly

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Install a new O-ring seal on the turbocharger oil supply standoffs.

If necessary, install the turbocharger oil supply standoffs.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 1: Locating Turbocharger Oil Supply Standoffs
  Courtesy of FORD MOTOR CO.
Using the Air Crossover Seal Remover/Installer and Handle, install the new low-pressure turbocharger tube seal in the turbocharger.

Fig 2: Installing Low-Pressure Turbocharger Tube Seal In Turbocharger
Courtesy of FORD MOTOR CO.
Install a new low-pressure-to-high-pressure turbocharger seal and gasket.

Fig 3: Locating Low-Pressure-To-High-Pressure Turbocharger Seal And Gasket
Courtesy of FORD MOTOR CO.

NOTE: The washers must be installed with the convex and concave surfaces facing towards each other. Failure to install the washers correctly may result in damage to the Turbocharger to Turbocharger Seal Installer.

NOTE: Prior to installing the Turbocharger to Turbocharger Seal Installer, assemble the turbochargers by hand. Verify that the turbocharger assembly goes back together evenly.

Fig 4: Installing Turbocharger To Turbocharger Seal Installer

Courtesy of FORD MOTOR CO.

Install the Turbocharger to Turbocharger Seal Installer and loosely install the nuts.

NOTE: Do not over-tighten the nuts or damage to the Turbocharger to Turbocharger Seal Installer may occur.

NOTE: A block of wood may be used to level the turbocharger during assembly of the turbochargers.

NOTE: The turbochargers do not go flush together. Remove the tool when the gap equals the measurement taken during the disassembly.

Using the Turbocharger to Turbocharger Seal Installer, assemble the turbocharger assembly.
- Tighten to 17 Nm (150 lb-in).
  
  Fig 5: Assembling Turbocharger Assembly Using Turbocharger To Turbocharger Seal Installer
  Courtesy of FORD MOTOR CO.

NOTE: Failure to use the Turbocharger Lifting Bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure.

Install the Turbocharger Lifting Bracket and 2 bolts.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 6: Installing Turbocharger Lifting Bracket
  Courtesy of FORD MOTOR CO.
Position the turbocharger actuator insulator.

Fig 7: Locating Turbocharger Actuator Insulator
Courtesy of FORD MOTOR CO.
Install the turbocharger actuator and 3 bolts.
- Tighten to 19 Nm (168 lb-in).
  
  Fig 8: Locating Turbocharger Actuator Bolts
  Courtesy of FORD MOTOR CO.
Position the turbocharger actuator linkage and install the nut.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 9: Locating Turbocharger Actuator Linkage Nut
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the seal with clean engine oil prior to assembly.

Fig 10: Locating Turbocharger Tube

Courtesy of FORD MOTOR CO.

Install the turbocharger tube.

NOTE: Large installer shown in illustration, small installer similar.

Fig 11: Installing Seal In Turbocharger Crossover Tube

Courtesy of FORD MOTOR CO.

Position the crossover tube in a soft-jawed vise. Using the Air Crossover Seal Remover/Installer and Handle, install a new seal in each end of the turbocharger crossover tube.
Install the turbocharger crossover tube.

Fig 12: Locating Turbocharger Crossover Tube
Courtesy of FORD MOTOR CO.