Turbocharger LH: Installation

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

Lubricate the turbocharger fitting and oil filter assembly O-ring with clean engine oil. Refer to: Specifications .

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Install the turbocharger fitting and oil filter assembly.
Torque: 35 lb.ft (48 Nm)

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Install the new turbocharger oil manifold assembly O-ring seal and gasket. Lubricate the new turbocharger oil manifold assembly O-ring seal with clean engine oil. Refer to: Specifications .

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NOTE: Lubricate the cylinder block bore with clean engine oil.

Install the turbocharger oil tube assembly, then install and tighten the turbocharger oil tube assembly lower bolt in the following 2 stages. Refer to: Specifications .

Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 30 deg.

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

If removed install and tighten the turbocharger exhaust flange stud bolts.

Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2

Torque: 18 lb.ft (25 Nm)

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Install the new turbocharger gasket.

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Inspect the turbocharger coolant tube turbocharger fitting and replace as needed.
Torque: 159 lb.in (18 Nm)

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Place the turbocharger in the vehicle. Connect the turbocharger coolant tube to the turbocharger fitting.

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Inspect the turbocharger coolant supply tube-to-engine block fitting and replace as needed.
Torque: 37 lb.ft (50 Nm)

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NOTE: Install the turbocharger and install the new turbocharger fasteners finger tight at this stage.

NOTE: Install the turbocharger coolant supply tube to the engine block fitting while installing the turbocharger.

Tighten the new turbocharger fasteners.
Torque: 24 lb.ft (32 Nm)

NOTE: Use a commercially available tool such as a MAC® XT50BS T50 TORX® bit socket or equivalent.

NOTE: Use a commercially available tool such a Pittsburg® 67011 9/16" hex to 3/8" square drive adapter or equivalent.

NOTE: Calculate the correct torque wrench setting for the following torque using the Torque Wrench Adapter Formulas in the chart below.

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Using the TORX® bit socket, the drive adapter and a 9/16" box end wrench, tighten the new turbocharger fastener.

Torque: 24 lb.ft (32 Nm)

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Install the new upper turbocharger oil tube assembly gasket.

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NOTE: Install the turbocharger oil tube assembly upper bolts finger tight at the turbocharger.
1. Tighten the outer turbocharger oil tube manifold bolt.
  Torque: 44 lb.in (5 Nm)
2. Tighten the inner turbocharger oil tube bolt in the following 2 stages.
  Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 30 deg.
3. Tighten the outer turbocharger oil tube bolt in the following 2 stages.
  Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 30 deg.
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Install the turbocharger coolant supply tube and the turbocharger oil feed tube bolt and tighten the bolt.
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 30 deg.

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Connect the electrical connector to the oil pressure switch and install the cover.

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Connect the turbocharger wastegate hose.

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Connect the turbocharger coolant return tube at the turbocharger.

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NOTE: Install the dual catalytic converter Y-Pipe with a new left gasket. Install the right and the left fasteners hand tight.

Evenly tighten the new left catalytic converter flange nuts.

Torque: 30 lb.ft (40 Nm)

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Evenly tighten the new right catalytic converter flange nuts.
Torque: 30 lb.ft (40 Nm)

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Install the engine crossmember. Refer to: Engine Crossmember .
1. Connect the turbocharger inlet tube and the turbocharger outlet tube at the turbocharger. Tighten the turbocharger inlet tube and the turbocharger outlet tube clamps.
  Torque: 44 lb.in (5.0 Nm)
2. Connect the crankcase ventilation tube quick release coupling. Refer to: Quick Release Coupling .
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Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .