Turbocharger RH: 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: 24 lb.ft (32 Nm)

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Install the new turbocharger oil tube assembly O-ring seal. Lubricate the new turbocharger oil tube 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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Install the new the turbocharger exhaust flange gasket.

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

Install the turbocharger exhaust flange and the new turbocharger exhaust flange stud bolts. Tighten the new turbocharger exhaust flange stud bolts.

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

Torque: 30 lb.ft (40 Nm)

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Install the new turbocharger gasket.

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Inspect the turbocharger coolant tube-to-turbocharger fittings 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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Install the new turbocharger mounting bolts, install the turbocharger coolant supply tube to the block fitting while installing the turbocharger.
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 turbocharger wastegate hose.

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

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1. Install the turbocharger coolant return tube and connect the turbocharger coolant return tube to the engine.
2. Connect the turbocharger coolant return tube to the turbocharger.
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NOTE: Position the dual catalytic converter Y-Pipe in vehicle with a new LH catalytic converter flange-to- TC gasket. Install all the fasteners hand tight.

Evenly tighten the new LH catalytic converter flange nuts onto the TC.

Torque: 30 lb.ft (40 Nm)

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

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Attach the exhaust hanger and tighten the exhaust flange bolts.
Torque: 30 lb.ft (40 Nm)

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- Connect the RH HO2S and the RH catalyst monitor sensors.
- Connect the wire routing connector.
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- Connect the LH HO2S and the LH catalyst monitor sensors.
- Connect the wire routing connectors.
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Install the Air Conditioning (A/C) compressor. Refer to: Air Conditioning (A/C) Compressor - 3.5L EcoBoost (235kW/320PS) .
Install the starter motor. Refer to: Starter Motor .
Install the turbocharger outlet tube. Tighten the clamps and connect the hose.
Torque: 44 lb.in (5 Nm)

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1. Install the turbocharger inlet tube and tighten the clamps.
  Torque: 36 lb.in (4.1 Nm)
2. Tighten the turbocharger inlet tube clamps.
  Torque: 44 lb.in (5 Nm)
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Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Start and check the exhaust system for leaks.