Removal And Installation: Turbocharger: Installation

If removed install and tighten the turbocharger mounting studs.
Torque

: 150 lb.in (17 Nm)

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Install the new turbocharger gasket.
Torque

: 150 lb.in (17 Nm)

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Install the turbocharger, then install and tighten the lower turbocharger mounting nuts.
Torque

:1 : 18 lb.ft (25 Nm) 2 : 18 lb.ft (25 Nm) 3 : 37 lb.ft (50 Nm) 4 : 37 lb.ft (50 Nm)

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Install the turbocharger heat shield, the upper turbocharger mounting nuts and the lower turbocharger heat shield retaining bolt finger tight at this stage.
Torque

:1 : 18 lb.ft (25 Nm) 2 : 18 lb.ft (25 Nm) 3 : 37 lb.ft (50 Nm) 4 : 37 lb.ft (50 Nm) 5 : 89 lb.in (10 Nm)

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NOTE: The rolled sealing washer goes on the turbocharger side of the banjo fitting, the flat sealing washer goes on the banjo bolt side.

Lubricate the new turbocharger oil supply tube O-ring seal with clean engine oil. Refer to: Specifications .

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NOTE: Do not reuse the turbocharger oil supply filter, a new turbocharger oil supply filter must be installed.

Install the new turbocharger oil supply filter.

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NOTE: The oil supply tube must be fully seated prior to fastener tightening.
- 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.
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
1. Install the turbocharger oil supply tube and the turbocharger oil supply tube retaining bolts finger tight at this stage.
  Torque
  
  :Tighten the turbocharger oil supply tube retaining bolt. : 89 lb.in (10 Nm) Tighten the turbocharger oil supply tube retaining banjo bolt. : 22 lb.ft (30 Nm)
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Lubricate the new turbocharger oil return tube O-ring seal with clean engine oil. Refer to: Specifications .

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NOTE: The oil return tube must be fully seated prior to fastener rundown.
- 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.
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.
  Torque
  
  : 89 lb.in (10 Nm)
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Connect the turbocharger control hoses. Use the General Equipment: Hose Clamp Remover/Installer

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1. Install the engine cover mounting stud.
  Torque
  
  : 89 lb.in (10 Nm)
2. Install the turbocharger inlet pipe nut.
  Torque
  
  : 89 lb.in (10 Nm)
3. Tighten the turbocharger inlet pipe clamp.
  Torque
  
  : 44 lb.in (5 Nm)
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Install the turbocharger coolant supply tube. Refer to: Turbocharger Coolant Supply Tube .
Install the halfshaft support bracket, then install and tighten the halfshaft support bracket bolts.
Torque

: 35 lb.ft (48 Nm)

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Install the power transfer unit. Refer to: Power Transfer Unit .
Check and top off the engine oil as needed. Refer to: Specifications .

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Start and check for leaks.