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Home >> Ford >> 2012 >> Flex SEL, AWD >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Fuel Charging System - Turbocharger (Supplement) >> Removal And Installation >> Turbocharger - RH >> RH Turbocharger (View 6 of 6) >> Installation

RH Turbocharger (View 6 of 6): 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
      G08042560Courtesy 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.
    Fig 2: Location of Upper RH Turbocharger-To-Cylinder Block Bracket Bolt
    G08042561Courtesy of FORD MOTOR CO.
  3. Loosen the 2 bolts for the upper RH turbocharger-to-cylinder block bracket.
  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: Location of Upper RH Turbocharger-To-Cylinder Block Bracket Bolt And RH Turbocharger Assembly
      G08042562Courtesy of FORD MOTOR CO.
  6. Install the 3 new RH exhaust manifold-to-turbocharger bolts.
    • Tighten to 45 Nm (33 lb-ft).
      Fig 4: Location of RH Exhaust Manifold-To-Turbocharger Bolts
      G08042563Courtesy 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: Location of Bolts And Upper RH Exhaust Manifold Heat Shields
      G08042564Courtesy of FORD MOTOR CO.
    9. NOTE: Align the index marks for the RH CAC tube.
  9. Install the RH CAC tube to the RH turbocharger and tighten the clamp.
    • To install, tighten to 5 Nm (44 lb-in).
      Fig 6: Location of RH CAC Tube Clamp
      G08042565Courtesy of FORD MOTOR CO.
    10. NOTE: Align the index marks for the RH CAC tube.
  10. Install the RH CAC and tighten the clamp.
    • To install, tighten to 5 Nm (44 lb-in).
      Fig 7: Location of RH CAC Tube Clamp
      G08042566Courtesy 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: Location of RH CAC Tube And RH CAC Tube Nut
      G08042567Courtesy of FORD MOTOR CO.
  12. Connect the RH turbocharger bypass valve hose.
    Fig 9: Location of RH Turbocharger Bypass Valve Hose
    G08042568Courtesy of FORD MOTOR CO.
  13. Connect the RH turbocharger bypass valve electrical connector.
    Fig 10: Location of RH Turbocharger Bypass Valve Electrical Connector
    G08042569Courtesy of FORD MOTOR CO.
  14. Install the turbocharger wastegate regulating valve hose to the RH CAC tube.
    Fig 11: Location of Turbocharger Regulating Valve Hose
    G08042570Courtesy of FORD MOTOR CO.
  15. Connect the LH turbocharger bypass valve electrical connector and the turbocharger bypass valve hose.
    Fig 12: Location of LH Turbocharger Bypass Valve Electrical Connector And Turbocharger Bypass Valve Hose
    G08042571Courtesy 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: Identifying Upper RH Turbocharger-To-Cylinder Block Bracket And Bolts Tightening Sequence
      G08042572Courtesy 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: Location of Coolant Tube Banjo Bolts And RH Turbocharger Coolant Tubes
      G08042573Courtesy of FORD MOTOR CO.
    20. NOTE: Lubricate the cylinder block bore with clean engine oil.
    Fig 15: Location of O-Ring Seals And RH Turbocharger Oil Return Tube
    G08042574Courtesy of FORD MOTOR CO.
  20. Using 2 new O-ring seals, install the RH turbocharger oil return tube in the cylinder block.
  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: Location of RH Turbocharger Oil Return Tube And Bolts
      G08042575Courtesy of FORD MOTOR CO.
  22. Install the lower RH turbocharger bracket and the 3 bolts and tighten in sequence shown in 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: Identifying Lower RH Turbocharger Bracket And Bolts Tightening Sequence
      G08042576Courtesy of FORD MOTOR CO.
    23. NOTE: Make sure the turbocharger wastegate regulating valve hose does not contact the exhaust manifold heat shield.
    Fig 18: Location of Turbocharger Wastegate Regulating Valve Hose Clamp
    G08042577Courtesy of FORD MOTOR CO.
  23. Connect the turbocharger wastegate regulating valve hose to the RH turbocharger.
    24. NOTE: Align the index marks for the RH turbocharger intake pipe.
  24. 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: Location of RH Turbocharger Intake Pipe Clamp
      G08042578Courtesy of FORD MOTOR CO.
  25. Install the lower RH exhaust manifold heat shield bolt.
    • Tighten to 14 Nm (124 lb-in).
      Fig 20: Location of Lower RH Exhaust Manifold Heat Shield Bolt
      G08042579Courtesy of FORD MOTOR CO.
    26. NOTE: Listen for audible click when installing the oil supply tube into the quick connect fitting.
    Fig 21: Location of RH Turbocharger Oil Supply Tube
    G08042580Courtesy of FORD MOTOR CO.
  26. Install the RH turbocharger oil supply tube into the quick connect fitting.
  27. Install the RH turbocharger oil supply tube secondary latch.
    Fig 22: Location of RH Turbocharger Oil Supply Tube Secondary Latch
    G08042581Courtesy of FORD MOTOR CO.
  28. Install the front subframe. For additional information, refer to UNI-BODY, SUBFRAME AND 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 .
  31. Install the underbody shield and the 4 retainers.
    Fig 23: Location of Retainers And Underbody Shield
    G08042582Courtesy of FORD MOTOR CO.
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