Turbocharger - Body On: Installation

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: Lubricate the low-pressure turbocharger oil drain tube with clean engine oil prior to installing.

NOTE: Install the low-pressure turbocharger drain tube with the taper side down.

Install the new low-pressure turbocharger drain tube in the turbocharger.

NOTE: Install 2 new O-rings seals and lubricate with clean engine oil prior to installing.

Install the turbocharger high-pressure oil drain tube.

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 seal failure.

NOTE: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.

NOTE: Make sure the turbocharger is positioned under the high-pressure fuel pump heat shield on the right side.

NOTE: Install a new gasket for the RH turbocharger inlet pipe at the RH exhaust manifold prior to installing the turbocharger assembly.

With the help of an assistant, using the Heavy Duty Floor Crane, install the turbocharger assembly.

NOTE: After removing the Turbocharger Lifting Bracket, the 2 bolt holes remain open on the turbocharger.

Remove the 2 bolts and the Turbocharger Lifting Bracket.
Install the 2 turbocharger hold downs and bolts.
- Tighten to 201 Nm (148 lb-ft).
Connect the EGR valve electrical connector.

Fig 1: Locating EGR Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Install the new oil filter base gasket and O-ring seal.
- Apply clean engine oil to the oil filter base gasket and O-ring seal.
  
  Fig 2: Locating Oil Filter Base Gasket And Seal
  Courtesy of FORD MOTOR CO.
Install the oil filter return tube assembly and screw.
- On new oil return tubes, tighten to 7 Nm (62 lb-in).
- On used oil return tubes, tighten to 5 Nm (44 lb-in).
  
  Fig 3: Locating Oil Filter Return Tube Assembly Screw
  Courtesy of FORD MOTOR CO.
Install the oil filter housing and 4 Torx bolts.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 4: Locating Oil Filter Housing Torx Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring seal on the oil filter cap and apply clean engine oil.

Install a new oil filter element and the oil filter cap.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 5: Identifying Oil Filter Element O-Ring Seal
  Courtesy of FORD MOTOR CO.
Connect the fuel injection pump supply tube at the fuel filter module.

Fig 6: Locating Fuel Injection Pump Supply Tube
Courtesy of FORD MOTOR CO.
Install the bolt for the engine wiring harness.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 7: Locating Engine Wiring Harness Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Rear bolts shown in illustration, front bolts similar.

Position the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 8: Locating Front Fuel Cooler Bracket Bolts
  Courtesy of FORD MOTOR CO.
Position back the oil level indicator and tube and install the nut.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 9: Locating Tube Nut
  Courtesy of FORD MOTOR CO.

NOTE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the fuel system.

Install fuel cooler-to-fuel filter module tube, new sealing washers and the banjo bolt.
- For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, tighten to 38 Nm (28 lb-ft).
  
  Fig 10: Locating Fuel Filter Module Tube Banjo Bolt
  Courtesy of FORD MOTOR CO.
Install the fuel filter element and cover.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 11: Locating Fuel Filter Module Cover
  Courtesy of FORD MOTOR CO.
Install the CAC tube flex coupling and clamps.
- Tighten the engine clamp to 12 Nm (106 lb-in).
- Tighten the tube clamp to 8 Nm (71 lb-in).
  
  Fig 12: Locating Charge Air Cooler Tube Flex Coupling Clamps
  Courtesy of FORD MOTOR CO.
Install the 2 new studs for the RH turbocharger inlet pipe.
- Tighten to 18 Nm (159 lb-in).
  
  Fig 13: Locating Outer RH Turbocharger Inlet Pipes-To-Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.

NOTE: Do not bend or twist the turbocharger inlet pipe or damage to the turbocharger inlet pipe may occur.

NOTE: To aid in installation, replace the top stud with bolt part number W302649.

NOTE: It will be necessary to position the EGR-OC pipe as needed.

Position the LH turbocharger inlet pipe in the vehicle. Install the new gasket and 2 new studs for the LH turbocharger inlet pipe. Loosely install the bolt.
- Tighten the studs to 18 Nm (159 lb-in).
  
  Fig 14: Locating LH Turbocharger Inlet Pipes-To-Exhaust Manifold Studs
  Courtesy of FORD MOTOR CO.
Install the new turbocharger inlet pipe gaskets, bracket and loosely install the 6 new bolts.
- Tighten the top 4 bolts to 25 Nm (18 lb-ft).
  
  Fig 15: Locating Turbocharger Inlet Pipe Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.

NOTE: To complete this step, it will be necessary to use the following tools:

A 3/8-in drive torque wrench that is 241.3 mm (9.5 in) or 368.3 mm (14.5 in) from center of the handle to the center of the square drive.
One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
A 12-mm Allen socket (to drive the Half-moon wrench).

NOTE: To obtain the required torque value of 25 Nm (18 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown in illustration and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.

Tighten the turbocharger inlet pipes-to-turbocharger bottom 2 bolts.

Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.

Fig 16: Locating Turbocharger Inlet Pipes-To-Turbocharger Bottom Bolts

Courtesy of FORD MOTOR CO.

TORQUE CHART - TURBOCHARGER INLET PIPES-TO-TURBOCHARGER

Half-Moon Wrench Brand	Wrench Part Number	Wrench Size	Torque Wrench Length	Torque Wrench setting
Half-Moon Wrench Brand	Wrench Part Number	Wrench Size	Torque Wrench Length	Nm	lb-in
Cornwell®	BWM-1012MM	10/12mm	9.5 in	20	177
Gear Wrench®	9851	10/12mm	9.5 in	18	159
Matco®	MHM1012	10/12mm	9.5 in	18	159
Mac®	HMM1012R	10/12mm	9.5 in	15	133
Snap-On®	CXM1012	10/12mm	9.5 in	18	159
Cornwell®	BWM-1012MM	10/12mm	14.5 in	19	168
Gear Wrench®	9851	10/12mm	14.5 in	18	159
Matco®	MHM1012	10/12mm	14.5 in	18	159
Mac®	HMM1012R	10/12mm	14.5 in	10	142
Snap-On®	CXM1012	10/12mm	14.5 in	18	159
NOTE: To achive the required torque of 25 Nm (18 lb-in), the torqur wrench must be set to the appropriate Torque Wrench Setting listed in this chart.

NOTE: LH shown in illustration, RH similar.

Install the 5 new lower turbocharger inlet pipe nuts.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 17: Locating LH And RH Turbocharger Inlet Pipes-To-Exhaust Manifold Nuts
  Courtesy of FORD MOTOR CO.

NOTE: To complete this step, it will be necessary to use the following tools:

A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
A 12-mm Allen socket (to drive the Half-moon wrench).

NOTE: To obtain the required torque value of 31 Nm (23 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown in illustration and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.

Tighten the LH turbocharger inlet pipe-to-LH exhaust manifold bolt.

Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.

Fig 18: Locating LH Turbocharger Inlet Pipe-To-LH Exhaust Manifold Bolt

Courtesy of FORD MOTOR CO.

TORQUE CHART - TURBOCHARGER INLET PIPES-TO-LH EXHAUST MANIFOLD

Half-Moon Wrench Brand	Wrench Part Number	Wrench Size	Torque Wrench Length	Torque Wrench setting
Half-Moon Wrench Brand	Wrench Part Number	Wrench Size	Torque Wrench Length	Nm	lb-in
Cornwell®	BWM-1012MM	10/12mm	14.5 in	26	19
Gear Wrench®	9851	10/12mm	14.5 in	23	17
Matco®	MHM1012	10/12mm	14.5 in	22	16
Mac®	HMM1012R	10/12mm	14.5 in	22	16
Snap-On®	CXM1012	10/12mm	14.5 in	22	16
Cornwell®	BWM-1012MM	10/12mm	15.5 in	27	20
Gear Wrench®	9851	10/12mm	15.5 in	23	17
Matco®	MHM1012	10/12mm	15.5 in	23	17
Mac®	HMM1012R	10/12mm	15.5 in	23	17
Snap-On®	CXM1012	10/12mm	15.5 in	23	17
NOTE: To achieve the required torque of 31 Nm (23 lb-in), the torque wrench must be set to the appropriate Torque Wrench Setting listed in this chart.

Install the new gasket and clamp for the exhaust downpipe.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 19: Locating Exhaust Downpipe
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.

Fig 20: Locating RH Turbocharger Inlet Pipe-To-EGR-Oxidation Catalytic Converter (OC) Pipe Bolts And EGR-OC-To-Turbocharger Bracket Bolts

Courtesy of FORD MOTOR CO.

Position the EGR-OC pipe and loosely install the 2 new bracket bolts. Install a new gasket and loosely install the 2 new bolts.
Tighten the 2 bolts for the exhaust downpipe at the OC .
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 21: Locating Exhaust Downpipe Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolts will result in damage to the horizontal EGR cooler and possible engine damage.

Fig 22: Locating EGR-OC Pipe Bracket-To-Bracket Bolt, Washer And Cylinder Head Bracket-To-Cylinder Head Bolt

Courtesy of FORD MOTOR CO.

Install the bracket, washers and loosely install the 2 new bolts for the EGR-OC pipe bracket.
Install the new gasket and the 2 new bolts for the EGR-OC pipe at the EGR cooler.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 23: Locating EGR-OC-To-EGR Cooler Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 2 EGR-OC pipe bolts at the RH turbocharger inlet pipe.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 24: Locating EGR-OC Pipe Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 2 bolts for the EGR-OC pipe bracket at the turbocharger.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 25: Locating EGR-OC Pipe Bracket Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.

Tighten the bolt for the EGR-OC pipe bracket.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 26: Locating EGR-OC Pipe Bracket Bolt
  Courtesy of FORD MOTOR CO.

NOTE: To complete this step, it will be necessary to use the following tools:

A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
One of the 11-mm/13-mm Half-moon wrenches listed in the following chart.
A 11-mm Allen socket (to drive the Half-moon wrench).

NOTE: To obtain the required torque value of 63 Nm (46 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown in illustration and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.

Tighten the EGR-OC pipe bracket-to-LH cylinder head bolt.

Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.

Fig 27: Locating EGR-OC Pipe Bracket-To-LH Cylinder Head Bolt

Courtesy of FORD MOTOR CO.

TORQUE CHART - EGR-OC PIPE BRACKET-TO-LH CYLINDER HEAD

Half-Moon Wrench Brand	Wrench Part Number	Wrench Size	Torque Wrench Length	Torque Wrench setting
Half-Moon Wrench Brand	Wrench Part Number	Wrench Size	Torque Wrench Length	Nm	lb-in
Cornwell®	BWM-1113MM	11/13mm	14.5 in	47	35
Gear Wrench®	9852	11/13mm	14.5 in	45	34
Matco®	MHM1113	11/13mm	14.5 in	46	34
Mac®	HMM1113R	11/13mm	14.5 in	46	34
Snap-On®	CXM1113	11/13mm	14.5 in	46	34
Cornwell®	BWM-1113MM	11/13mm	15.5 in	49	36
Gear Wrench®	9852	11/13mm	15.5 in	47	35
Matco®	MHM1113	11/13mm	15.5 in	47	35
Mac®	HMM1113R	11/13mm	15.5 in	47	35
Snap-On®	CXM1113	11/13mm	15.5 in	47	35
NOTE: To achive the required torque of 62 Nm (46 lb-in), the torque wrench must be set to the appropriate Torque Wrench Setting listed in this chart.

Install the EP sensor tube fitting into the EGR-OC pipe.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 28: Locating EP Sensor Tube Fitting
  Courtesy of FORD MOTOR CO.
Connect the EP sensor tube to the EGR-OC pipe.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 29: Locating Exhaust Pressure Sensor Tube
  Courtesy of FORD MOTOR CO.
If equipped, position back the front driveshaft and install the 2 straps and 4 bolts.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 30: Locating Front Drive Shaft Bolts And Straps
  Courtesy of FORD MOTOR CO.
Install the EGRT sensor into the RH turbocharger inlet pipe.
- Tighten to 44 Nm (32 lb-ft).
  
  Fig 31: Locating Exhaust Gas Recirculation Temperature Sensor
  Courtesy of FORD MOTOR CO.
Install the RH splash shield. For additional information, refer to FRONT END BODY PANELS .
Connect the turbocharger actuator electrical connector and pin-type retainer.

Fig 32: Locating Turbocharger Actuator Electrical Connector And Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Position the fuel cooler bracket.

Fig 33: Locating Fuel Cooler Bracket
Courtesy of FORD MOTOR CO.
Position back the fuel cooler, fuel cooling system expansion tank and turbocharger actuator cooler. Install the 3 bolts for the turbocharger actuator cooler. Tighten the bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Finger-tighten the bolts.
- Stage 2: Tighten to 7 Nm (62 lb-in).
  
  Fig 34: Identifying Turbocharger Actuator Cooler Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the 2 nuts for the fuel cooler.
- Tighten to 19 Nm (168 lb-in).
  
  Fig 35: Locating Fuel Cooler Retaining Nuts
  Courtesy of FORD MOTOR CO.

NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.

Install the 2 stud bolts for the fuel cooler.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 36: Locating Fuel Cooler Stud Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 bolts for the fuel cooler.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 37: Identifying Fuel Cooler Bolts
  Courtesy of FORD MOTOR CO.
Install the 3 bolts for the fuel cooling system expansion tank.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 38: Locating Fuel Cooling System Expansion Tank Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.

Install the new sealing washers and 2 banjo bolts at the fuel cooler.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 39: Locating Fuel Cooler Banjo Bolts
  Courtesy of FORD MOTOR CO.
Position the turbocharger heat shield and install the 5 bolts.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 40: Locating Turbocharger Heat Shield Bolts
  Courtesy of FORD MOTOR CO.

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

Position the turbocharger oil supply tube and install the bolt.
- Tighten to 13 Nm (115 lb-in).
  
  Fig 41: Locating Turbocharger Oil Supply Tube Bolt
  Courtesy of FORD MOTOR CO.
Prelubricate the oil inlet holes of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearings with oil.

NOTE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.

NOTE: Use a back-up wrench to prevent the fittings from turning.

NOTE: The back banjo bolt will require a torque adapter to be tightened properly.

Install new sealing washers and the 2 turbocharger oil supply tube banjo bolts.
- Calculate the correct torque wrench setting for the following torque. Refer to the illustration.
  
  Fig 42: Identifying Torque Wrench Adapter Formulas
  Courtesy of FORD MOTOR CO.
- For Viton® sealing washers, using a torque adapter, tighten to 25 Nm (18 lb-ft).
- For copper sealing washer, using a torque adapter, tighten to 38 Nm (28 lb-ft).
- Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
  
  Fig 43: Locating Turbocharger Oil Supply Tube Banjo Bolts
  Courtesy of FORD MOTOR CO.
Position the auxiliary air intake hose in the vehicle.

Fig 44: Locating ACL Outlet Pipe
Courtesy of FORD MOTOR CO.
Install the ACL assembly and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Install the degas bottle. For additional information, refer to ENGINE COOLING .
Bleed the low pressure fuel system. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .