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Turbocharger - RH: Installation

  1. Install the oil supply tube filter, washer and bolt.
    1. Install the new oil supply tube filter in the oil supply tube block.
    2. Slide the new washer onto the oil supply tube block.
    3. Install the bolt into the oil supply tube block.
    Fig 1: Identifying Oil Supply Tube Filter, Washer And Bolt
    G07464855Courtesy of FORD MOTOR CO.
  2. Install the RH turbocharger oil supply tube.
    • Tighten the bolt to 35 Nm (26 lb-ft).
  3. NOTE: The upper RH turbocharger bracket bolts must be loosened in order to perform the tightening sequence or damage to the turbocharger may occur.

    Loosen the 2 bolts for the upper RH turbocharger-to-cylinder block bracket.

    Fig 2: Locating Upper RH Turbocharger-To-Cylinder Block Bracket Bolts
    G07464856Courtesy of FORD MOTOR CO.
  4. Install a new RH exhaust manifold-to-turbocharger gasket.
  5. Install the RH turbocharger assembly and the upper RH turbocharger-to-cylinder block bracket bolt.
    • Do not tighten the bolts at this time.
    Fig 3: Locating Upper RH Turbocharger-To-Cylinder Block Bracket Bolt And RH Turbocharger Assembly
    G07464857Courtesy of FORD MOTOR CO.
  6. Install the 3 new RH exhaust manifold-to-turbocharger bolts.
    • Tighten to 45 Nm (33 lb-ft).
    Fig 4: Locating RH Exhaust Manifold-To-Turbocharger Bolts
    G07464858Courtesy of FORD MOTOR CO.
  7. Install the RH engine lifting eye and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
  8. Install the 2 upper RH exhaust manifold heat shields and the 4 bolts.
    • Tighten to 14 Nm (124 lb-in).
    Fig 5: Locating Bolts And Upper RH Exhaust Manifold Heat Shields
    G07464859Courtesy of FORD MOTOR CO.
  9. NOTE: Align the index marks for the RH CAC  tube.

    Install the RH CAC  tube to the RH turbocharger and tighten the clamp.

    • To install, tighten to 5 Nm (44 lb-in).
    Fig 6: Locating RH CAC Tube To RH Turbocharger And Clamp
    G07464860Courtesy of FORD MOTOR CO.
  10. NOTE: Align the index marks for the RH CAC  tube.

    Install the RH CAC  and tighten the clamp.

    • To install, tighten to 5 Nm (44 lb-in).
    Fig 7: Locating Clamp And RH CAC Tube
    G07464861Courtesy of FORD MOTOR CO.
  11. Install the RH CAC  tube and the RH CAC  tube nut to the intake manifold.
    • Tighten to 6 Nm (53 lb-in).
    Fig 8: Locating RH CAC Tube Nut From Intake Manifold
    G07464862Courtesy of FORD MOTOR CO.
  12. Connect the RH turbocharger bypass valve hose.
    Fig 9: Locating RH Turbocharger Bypass Valve Hose
    G07464863Courtesy of FORD MOTOR CO.
  13. Connect the RH turbocharger bypass valve electrical connector.
    Fig 10: Locating RH Turbocharger Bypass Valve Electrical Connector
    G07464864Courtesy of FORD MOTOR CO.
  14. Install the turbocharger wastegate regulating valve hose to the RH CAC  tube.
    Fig 11: Locating Turbocharger Wastegate Regulating Valve Hose From RH Charge Air Cooler (CAC) Tube
    G07464865Courtesy of FORD MOTOR CO.
  15. Connect the LH turbocharger bypass valve electrical connector and the turbocharger bypass valve hose.
    Fig 12: Locating LH Turbocharger Bypass Valve Electrical Connector And Turbocharger Bypass Valve Hose
    G07464866Courtesy of FORD MOTOR CO.
  16. Install the strut tower brace and the 4 nuts.
    • Tighten to 30 Nm (22 lb-ft).
  17. Attach the 2 brake booster vacuum hose retainers to the strut tower brace.
  18. Position the upper RH turbocharger-to-cylinder block bracket as far clockwise as possible and tighten the bolts in the following sequence.
    1. Tighten the lower cylinder block bracket bolt to 26 Nm (19 lb-ft).
    2. Tighten the upper cylinder block bracket bolt to 26 Nm (19 lb-ft).
    3. Tighten the cylinder block bracket-to-turbocharger bolt to 19 Nm (168 lb-in).
    Fig 13: Locating Brake Booster Vacuum Hose Retainers To Strut Tower Brace
    G07464867Courtesy of FORD MOTOR CO.
  19. Using 2 new sealing washers, install the 2 RH turbocharger coolant tube banjo bolts.
    • Tighten to 40 Nm (30 lb-ft).
    Fig 14: Locating Coolant Tube Banjo Bolts And RH Turbocharger Coolant Tubes
    G07464868Courtesy of FORD MOTOR CO.
  20. NOTE: Lubricate the cylinder block bore with clean engine oil.

    Using 2 new O-ring seals, install the RH turbocharger oil return tube in the cylinder block.

    Fig 15: Locating RH Turbocharger Oil Return Tube From Cylinder Block
    G07464869Courtesy of FORD MOTOR CO.
  21. Install a new gasket and install the RH turbocharger oil return tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 16: Locating Bolts And RH Turbocharger Oil Return Tube From Turbocharger
    G07464870Courtesy of FORD MOTOR CO.
  22. Install the lower RH turbocharger bracket and the 3 bolts and tighten in sequence shown in the illustration.
    1. Tighten the lower RH turbocharger bracket-to-turbocharger bolt to 19 Nm (168 lb-in).
    2. Tighten the 2 lower RH turbocharger bracket-to-cylinder block bolts to 48 Nm (35 lb-in).
    Fig 17: Locating Lower RH Turbocharger Bracket And Bolts
    G07464871Courtesy of FORD MOTOR CO.
  23. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.

    Connect the turbocharger wastegate regulating valve hose to the RH turbocharger.

    Fig 18: Locating Turbocharger Wastegate Regulating Valve Hose From RH Turbocharger Assembly
    G07464872Courtesy of FORD MOTOR CO.
  24. NOTE: Align the index marks for the RH turbocharger intake pipe.

    Install the RH turbocharger intake pipe to the RH turbocharger and tighten the clamp.

    • To install, tighten to 5 Nm (44 lb-in).
    Fig 19: Locating Clamp And RH Turbocharger Intake Pipe From RH Turbocharger
    G07464873Courtesy of FORD MOTOR CO.
  25. Install the lower RH exhaust manifold heat shield bolt.
    • Tighten to 14 Nm (124 lb-in).
    Fig 20: Locating Lower RH Exhaust Manifold Heat Shield Bolt
    G07464874Courtesy of FORD MOTOR CO.
  26. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.

    Install the RH turbocharger oil supply tube into the quick connect fitting.

    Fig 21: Locating RH Turbocharger Oil Supply Tube Into Quick Connect Fitting
    G07464875Courtesy of FORD MOTOR CO.
  27. Install the RH turbocharger oil supply tube secondary latch.
    Fig 22: Locating RH Turbocharger Oil Supply Tube Secondary Latch
    G07464876Courtesy of FORD MOTOR CO.
  28. Install the front subframe. For additional information, refer to BODY SYSTEM - UNI-BODY, BODY SUBFRAME & MOUNTING SYSTEM .
  29. Install the RH catalytic converter. For additional information, refer to EXHAUST SYSTEM .
  30. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING SYSTEM .
  31. Install the underbody shield and the 4 retainers.
Fig 23: Locating Retainers And Underbody Shield
G07464877Courtesy of FORD MOTOR CO.
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