Removal And Installation: Turbocharger: Installation

All vehicles 

1. 1.
   
   If removed install and then tighten the TC exhaust flange studbolts.

   Torque: 18 lb.ft (25 Nm)

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1. 2.
   
   If removed install and then tighten the TC mounting studs.

   Torque: 150 lb.in (17 Nm)

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1. 3.
   
   Install the new TC gasket.

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1. 4.
   
   Install the TC, then install and tighten the lower TC mounting nuts.

   Torque:

   1: 37 lb.ft (50 Nm)

   2 : 37 lb.ft (50 Nm)

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AWD (all-wheel drive) vehicles 

1. 5.
   
   Position and attach the TC control valve vacuum tube retainers. Connect the CHT electrical connector and then attach the CHT wiring harness retainer.

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1. 6.
   
   Raise the floor jack 11 mm (.433 in).

   Use the General Equipment: Trolley Jack

   Use the General Equipment: Wooden Block

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1. 7.
   
   Install the engine mount. Refer to: ENGINE MOUNT - 2.0L EcoBoost (184kW/250PS) - MI4.

All vehicles 

1. 8.
   
   Install a new TC oil return tube O-ring seal and a new TC oil return tube gasket. Lubricate the new TC oil return tube O-ring seal with clean engine oil. Refer to: SPECIFICATIONS - 2.0L EcoBoost (184kW/250PS) - MI4.

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1. 9.
   
   
   NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
   NOTE: The oil return tube must be fully seated prior to fastener rundown.

   Install the TC oil return tube, then install and tighten the TC oil return tube bolts.

   Material: Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

   Torque: 89 lb.in (10 Nm)

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1. 10.
   
   Connect the TC wastegate control hose.

   Use the General Equipment: Hose Clamp Remover/Installer

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1. 11.
   
   
   NOTE: Do not reuse the TC oil filter, a new TC oil filter must be installed.

   Install the new TC oil filter.

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1. 12.
   
   Install a new TC oil supply tube O-ring seal and the new TC oil supply tube sealing washers. Lubricate the new TC oil supply tube O-ring seal with clean engine oil. Refer to: SPECIFICATIONS - 2.0L EcoBoost (184kW/250PS) - MI4.

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1. 13.
   
   
   NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.
   NOTE: The oil supply tube must be fully seated prior to fastener tightening.

   Install the TC oil supply tube and the TC oil supply tube retaining bolts finger tight at this stage.

   Material: Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

   Torque:

   Bolt : 89 lb.in (10 Nm)

   Banjo bolt : 18 lb.ft (25 Nm)

   Tighten the Banjo bolt an additional : 50°

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1. 14.
   
   
   NOTE: Install the TC heat shield, the upper TC mounting nuts and the lower TC heat shield retaining bolt finger tight at this stage.

   1. 1.
      
      Tighten the upper TC mounting nuts.

      Torque: 37 lb.ft (50 Nm)

   1. 2.
      
      Tighten the lower TC heat shield retaining bolt.

      Torque: 89 lb.in (10 Nm)

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1. 15.
   
   Install the new TC coolant tube sealing washers. Install the new TC coolant tube O-ring seals and lubricate with clean engine coolant. Refer to: SPECIFICATIONS - 2.0L EcoBoost (184kW/250PS) - MI4.

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1. 16.
   
   
   NOTE: Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. DO-NOT USE A METAL BRUSH; DAMAGE TO SEALING AREA WILL RESULT IN LEAKS.

   1. 1.
      
      Hand start the TC cooling tube-to-block bolt at this stage.

      Material: Metal Brake Parts Cleaner (U.S.) / PM-4-A, PM-4-B (U.S.)

   1. 2.
      
      
      NOTE: Lubricate the TC cooling tube O-ring seals with clean engine coolant.

      Fit the O-ring end of the TC coolant tubes to the TC. The lower coolant inlet tube goes into the TC first.

   1. 3.
      
      Install and tighten the TC coolant tube-to- TC bolt.

      Torque: 89 lb.in (10 Nm)

   1. 4.
      
      Tighten the TC coolant tube-to-block bolt.

      Torque: 27 lb.ft (37 Nm)

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1. 17.
   
   Install the catalytic converter. Refer to: CATALYTIC CONVERTER - 2.0L EcoBoost (184kW/250PS) - MI4.

1. 18.
   
   Install the TC inlet pipe and then tighten the clamps.

   Torque

   : 42 lb.in (4.8 Nm)

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1. 19.
   
   Install and tighten the TC inlet pipe retainers. Connect the crankcase vent tube quick release coupling. Refer to: QUICK RELEASE COUPLING - 2.0L EcoBoost (184kW/250PS) - MI4.

   Torque:

   Bolt : 80 lb.in (9 Nm)

   Ball stud : 42 lb.in (4.8 Nm)

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1. 20.
   
   Install the TC outlet pipe. Install and tighten the TC outlet pipe retaining nuts. Tighten the TC outlet pipe clamps.

   Torque:

   Nuts : 97 lb.in (11 Nm)

   Clamps : 44 lb.in (5 Nm)

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1. 21.
   
   Connect the TC bypass valve electrical connector and attach the harness retainer to the studbolt. Connect the TC bypass hose and clamp.

   Use the General Equipment: Hose Clamp Remover/Installer

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1. 22.
   
   If equipped, install the underbody shield and the retainers.

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1. 23.
   
   Install the underbody shield and the retainers.

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1. 24.
   
   Install the RHF tire. Refer to: Wheel and Tire .

1. 25.
   
   Install the cowl panel. Refer to: Cowl Panel .

1. 26.
   
   
   1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

      Lubricate each grommet with silicone grease.

      Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

   2. Position the engine appearance cover onto engine with the grommets aligned with the studs.
   3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.

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1. 27.
   
   Fill the cooling system. Refer to: COOLING SYSTEM DRAINING AND VACUUM FILLING - 2.0L EcoBoost (184kW/250PS) - MI4.

1. 28.
   
   Check and top off the engine oil as needed. Refer to: SPECIFICATIONS - 2.0L EcoBoost (184kW/250PS) - MI4.