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Turbocharger - RH: Installation

WARNING: This page is about a different car, the 2012 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

    NOTE: Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange stud bolt threads prior to installation of the turbocharger exhaust flange.
    Fig 1: Locating Turbocharger Exhaust Flange Stud Bolts And Turbocharger Exhaust Flange
    G07411423Courtesy of FORD MOTOR CO.
  1. If removed, using a new turbocharger exhaust flange gasket, install the turbocharger exhaust flange and the 2 new turbocharger exhaust flange stud bolts.
    • Tighten to 40 Nm (30 lb-ft).
  2. If removed, install the turbocharger coolant supply and the coolant outlet tubes.
    3. NOTE: Lubricate the cylinder block bore with clean engine oil.
    NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.
    NOTE: Make sure the turbocharger oil supply tube is positioned in the cylinder block during the installation of the turbocharger oil return tube assembly.
  3. Using a new turbocharger oil return tube O-ring seal, install the turbocharger oil return tube assembly.
  4. Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3 turbocharger mounting bolts.
    • Tighten finger tight.
  5. Install the turbocharger bracket bolt.
    • Tighten finger tight.
  6. Tighten the 3 turbocharger mounting bolts.
    • Tighten to 32 Nm (24 lb-ft).
  7. Tighten the turbocharger bracket bolt.
    • Tighten to 18 Nm (159 lb-in).
  8. Tighten the 2 turbocharger bracket-to-cylinder block bolts.
    • Tighten to 10 Nm (89 lb-in).
    9. NOTE: The best access for the tube is from above.
  9. Connect the RH turbocharger coolant return tube into the turbocharger.
  10. Using a new turbocharger oil return tube gasket, install the 2 turbocharger center housing bolts at the turbocharger. Tighten in the following stages:
    • Stage 1: Install the bolt for the oil pressure tube side halfway.
    • Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).
    • Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.
    • Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).
    • Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.
  11. Install the turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages:
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 30 degrees.
  12. Install the turbocharger oil supply tube bracket and bolt. Tighten in the following stages:
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 30 degrees.
  13. Position back the turbocharger bypass valve on the bracket. Connect the 2 bypass vacuum hoses and the wastegate hose.
    • Connect the turbocharger bypass valve electrical connector.
  14. Connect the turbocharger coolant supply tube to the turbocharger.
  15. Install the starter. For additional information, REFER to STARTING SYSTEM .

    4WD vehicles 

  16. Remove the 2 transmission insulator and retainer nuts.
    Fig 2: Locating Transmission Insulator And Retainer Nuts
    G06128175Courtesy of FORD MOTOR CO.
    17. NOTE: Right side shown in illustration, left side similar. Transmission crossmember removed for clarity.
    Fig 3: Locating Transmission Insulator And Retainer Bolts
    G06128176Courtesy of FORD MOTOR CO.
  17. Remove the 4 transmission insulator and retainer bolts.
  18. Support the transfer case.
    Fig 4: Supporting Transfer Case
    G06170378Courtesy of FORD MOTOR CO.
  19. Remove the 4 transmission crossmember nuts and bolts.
    Fig 5: Locating Transmission Crossmember Nuts And Bolts
    G06170379Courtesy of FORD MOTOR CO.
  20. Remove the transmission insulator and retainer.

    RWD 

  21. Remove the 2 transmission insulator and retainer nuts.
    Fig 6: Locating Transmission Insulator And Retainer Nuts
    G06127312Courtesy of FORD MOTOR CO.
  22. Position a suitable high-lift transmission jack under the transmission.
  23. Remove the 4 transmission crossmember nuts and bolts (2 each side) and remove the transmission crossmember.
    Fig 7: Locating Transmission Crossmember Nuts And Bolts
    G06135596Courtesy of FORD MOTOR CO.
  24. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and retainer.
    Fig 8: Locating Transmission Insulator And Retainer Bolts
    G06127315Courtesy of FORD MOTOR CO.

    All vehicles 

  25. Install the exhaust Y-pipe - dual catalytic converter. For additional information, REFER to EXHAUST SYSTEM .
  26. Position the A/C compressor and install the 3 A/C compressor bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 9: Locating A/C Compressor Bolts
    G07411416Courtesy of FORD MOTOR CO.
  27. Install the A/C compressor belt. For additional information, REFER to ACCESSORY DRIVE .
  28. Install the ACL outlet pipe, RH ACL pipe to-turbocharger pipe, RH turbocharger bypass hose and the RH turbocharger-to-CAC pipe. For additional information, refer to Intake Air System Components - Exploded View, 3.5L GTDI in INTAKE AIR DISTRIBUTION & FILTERING .
  29. Fill the engine cooling system. For additional information, REFER to ENGINE COOLING .
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