Turbocharger - RH: Installation

All vehicles 

1. NOTE: Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange stud bolt threads prior to installation of the turbocharger exhaust flange.

   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).
     Fig 1: Locating Turbocharger Exhaust Flange Stud Bolts And Turbocharger Exhaust Flange

     Courtesy of FORD MOTOR CO.
2. If removed, install the turbocharger coolant tube.
   Fig 2: Locating Turbocharger Coolant Tube

   Courtesy of FORD MOTOR CO.
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.

   Using a new turbocharger oil return tube O-ring seal, install the turbocharger oil return tube assembly.

   Fig 3: Locating Turbocharger Oil Return Tube

   Courtesy of FORD MOTOR CO.
4. Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3 turbocharger mounting bolts.
   • Tighten finger tight.
     Fig 4: Locating RH Turbocharger Mounting Bolts

     Courtesy of FORD MOTOR CO.
5. Install the turbocharger bracket bolt.
   • Tighten finger tight.
     Fig 5: Locating Turbocharger Bracket Bolt

     Courtesy of FORD MOTOR CO.
6. Tighten the 3 turbocharger mounting bolts.
   • Tighten to 32 Nm (24 lb-ft).
     Fig 6: Locating RH Turbocharger Mounting Bolts

     Courtesy of FORD MOTOR CO.
7. Tighten the turbocharger bracket bolt.
   • Tighten to 28 Nm (21 lb-ft).
     Fig 7: Locating Turbocharger Bracket Bolt

     Courtesy of FORD MOTOR CO.
8. Tighten the 2 turbocharger bracket-to-cylinder block bolts.
   • Tighten to 10 Nm (89 lb-in).
     Fig 8: Locating Turbocharger Bracket-To-Cylinder Block Mounting Bolts

     Courtesy of FORD MOTOR CO.
9. 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.
     Fig 9: Locating Turbocharger Oil Return Tube Bolts

     Courtesy of FORD MOTOR CO.
10. 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.
      Fig 10: Locating Turbocharger Oil Return Tube Bolt At Cylinder Block

      Courtesy of FORD MOTOR CO.
11. Install the bolt for the RH turbocharger coolant and oil tubes. Tighten in the following stages:
    • Stage 1: Tighten to 8 Nm (71 lb-in).
    • Stage 2: Tighten an additional 30 degrees.
      Fig 11: Locating Turbocharger Coolant And Oil Tubes Bracket Bolt

      Courtesy of FORD MOTOR CO.
12. Connect the wastegate hose.
    Fig 12: Locating Wastegate Hose

    Courtesy of FORD MOTOR CO.
13. Install the turbocharger coolant supply tube.
    Fig 13: Locating Turbocharger Coolant Supply Tube

    Courtesy of FORD MOTOR CO.
14. Install the starter. Refer to STARTING SYSTEM .

    4WD vehicles 

15. Remove the 2 transmission insulator and retainer nuts.
    Fig 14: Locating Transmission Insulator And Retainer Nuts

    Courtesy of FORD MOTOR CO.
16. NOTE: Right side shown in illustration, left side similar. Transmission crossmember removed for clarity.

    Remove the 4 transmission insulator and retainer bolts.

    Fig 15: Locating Transmission Insulator And Retainer Bolts

    Courtesy of FORD MOTOR CO.
17. Support the transfer case.
    Fig 16: Supporting Transfer Case

    Courtesy of FORD MOTOR CO.
18. Remove the 4 transmission crossmember nuts and bolts.
    Fig 17: Locating Transmission Support Crossmember Nuts And Bolts

    Courtesy of FORD MOTOR CO.
19. Remove the transmission insulator and retainer.

    RWD 

20. Remove the 2 transmission insulator and retainer nuts.
    Fig 18: Locating Transmission Insulator And Retainer Nuts

    Courtesy of FORD MOTOR CO.
21. Position a suitable high-lift transmission jack under the transmission.
22. Remove the 4 transmission crossmember nuts and bolts (2 each side) and remove the transmission crossmember.
    Fig 19: Locating Transmission Crossmember Nuts And Bolts

    Courtesy of FORD MOTOR CO.
23. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and retainer.
    Fig 20: Locating Transmission Insulator And Retainer Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

24. Install the exhaust Y-pipe - dual catalytic converter. Refer to EXHAUST SYSTEM .
25. Position the A/C compressor and install the 3 A/C compressor bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 21: Locating A/C Compressor Mounting Bolts

      Courtesy of FORD MOTOR CO.
26. Install the A/C compressor belt. Refer to ACCESSORY DRIVE BELT .
27. Install the ACL outlet pipe, RH ACL pipe to-turbocharger pipe, RH turbocharger bypass hose and the RH turbocharger-to-CAC pipe. Refer to Intake Air System Components - Exploded View, 3.5L GTDI in REMOVAL AND INSTALLATION .
28. Fill the engine cooling system. Refer to ENGINE COOLING SYSTEM .