Turbocharger RH: Installation

NOTE: Make sure that the mating faces are clean and free of foreign material.

If removed install and tighten the turbocharger exhaust flange studs
Torque: 18 lb.ft (25 Nm)

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Install a new turbocharger coolant supply tube O-ring seal and lubricate with clean engine coolant. Refer to: Specifications .

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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: Install short end of stud into engine cylinder head.

Install the turbocharger and gasket, loosely install the turbocharger retaining bolt and the studs. Install the turbocharger coolant supply tube to the engine block while installing the turbocharger.
1. Tighten the turbocharger retaining studs.
  Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
  
  Torque: 106 lb.in (12 Nm)
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Install the turbocharger retaining nuts. Tighten the turbocharger retainers in the following sequence.
Torque:

1: 44 lb.ft (60 Nm)

2: 44 lb.ft (60 Nm)

3: 27 lb.ft (37 Nm)

Re-tighten 1: 44 lb.ft (60 Nm)

Re-tighten 2: 44 lb.ft (60 Nm)

Re-tighten 3: 27 lb.ft (37 Nm)

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Install and tighten the turbocharger coolant supply tube bolt.
Torque: 18 lb.ft (24 Nm)

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Install the steering heat shield, then install and tighten the heat shield retainers.
Torque: 71 lb.in (8 Nm)

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NOTE: Left side shown, right side is similar.

Install and tighten the left side and the right side upper stabilizer bar nuts.

Torque: 159 lb.in (18 Nm)

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Install the new turbocharger oil return tube-to-engine block gasket.

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Install a new turbocharger oil return tube O-ring seal and lubricate with clean engine oil. Refer to: Specifications .

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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.

Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube retainers.

Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

Torque: 89 lb.in (10 Nm)

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Connect the turbocharger wastegate control hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

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Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant. Refer to: Specifications .

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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.

Install the turbocharger coolant return tube, then install and tighten the turbocharger coolant return tube bolt.

Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

Torque: 89 lb.in (10 Nm)

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Install a new catalytic converter gasket.

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NOTE: Evenly tighten the fasteners.

Install the right catalytic converter, then install and tighten the right catalytic converter nuts.

Torque: 30 lb.ft (40 Nm)

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Install and tighten the right catalytic converter to transmission bracket bolts.
Torque: 22 lb.ft (30 Nm)

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Install the new turbocharger oil supply tube O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the O-ring seals with clean engine oil. Refer to: Specifications .

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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 turbocharger O-ring bore and 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: When installing the turbocharger oil supply tube into the engine block, use care not to damage the new turbocharger oil supply tube oil filter.

Install the turbocharger oil supply tube, then install and tighten the turbocharger oil supply tube bolts.

Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

Torque: 89 lb.in (10 Nm)

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Install the turbocharger heat shield, then install and tighten the heat shield retainers.
Torque: 106 lb.in (12 Nm)

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Install the Engine Oil Pressure (EOP) Sensor. Refer to: Engine Oil Pressure (EOP) Sensor .
Install the underbody shield and then install the underbody shield retainers.

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Install the front Wheel and Tires. Refer to: Wheel and Tire .
Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
Check and top off the engine oil as needed. Refer to: Specifications .