Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different variant/trim than selected.

If the turbocharger outlet pipe was removed, then inspect and replace the turbocharger outlet pipe gasket as needed.

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If removed, install the turbocharger outlet pipe to the turbocharger, then install and tighten the turbocharger outlet pipe nuts.
Torque

: 97 lb.in (11 Nm)

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If removed, install and tighten the turbocharger exhaust studs.
Torque

: 89 lb.in (10 Nm)

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If removed, install and tighten the turbocharger mounting studs.
Torque

: 89 lb.in (10 Nm)

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Lubricate the turbocharger oil supply tube 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 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: Make sure that a new turbocharger oil supply tube assembly is installed.

Install the new turbocharger oil supply tube and the turbocharger oil supply tube bolts finger tight.
1. Tighten the turbocharger oil supply tube bolt.
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
  
  Torque
  
  : 89 lb.in (10 Nm)
2. Tighten the turbocharger oil supply tube bolt.
  Torque
  
  : 89 lb.in (10 Nm)
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Install the new the turbocharger heat shield and gasket assembly, then install and tighten the turbocharger heat shield bolt.
Torque

: 89 lb.in (10 Nm)

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NOTE: Only tighten the 4 turbocharger nuts finger tight at this stage.

Install the turbocharger and the new turbocharger nuts. Tighten in the following 5 stages.

Torque

Stage 1: Tighten in the sequence shown: : 35 lb.in (4 Nm)

Stage 2: Tighten in the sequence shown: : 168 lb.in (19 Nm)

Stage 3: Tighten in the sequence shown: : 18 lb.ft (24 Nm)

Stage 4: Wait 30 s

Stage 5: Tighten in the sequence shown: : 18 lb.ft (24 Nm)

Fig 1: Turbocharger Nut Tightening Sequence
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NOTE: A new turbocharger oil supply tube filter must be installed. Failure to install a new filter will cause turbocharger failure

Install the new turbocharger oil supply filter.

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Install and tighten the plug. Torque: 80 lb.in (9 Nm)

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WARNING: Take extra care when handling the compressed spring.

Remove the locking pin.

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Remove Special Service Tool: 303-1605 Alignment Tool, Camshaft.

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Install the new turbocharger oil supply tube sealing washers, then install and tighten the new turbocharger oil supply tube bolt.
Torque

: 19 lb.ft (26 Nm)

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

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

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Install the new turbocharger oil return tube gasket.

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Install and tighten the turbocharger oil return tube retainers.
Torque

: 89 lb.in (10 Nm)

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1. Connect the turbocharger coolant tubes and the hose clamps. Use the General Equipment: Hose Clamp Remover/Installer
2. Unclamp the turbocharger coolant tubes. Use the General Equipment: Hose Clamp(s)
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Position back the turbocharger coolant return tube heat shield.

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Install the engine front cover. Refer to: Engine Front Cover .
Check and top off the engine oil as needed. Refer to: Specifications .