Removal And Installation: Turbocharger: Installation

All Vehicles 

1. If removed, install and tighten the turbocharger studs.

   Torque: 1, tighten to: 36 lb.in (4.1 Nm) | 2, tighten to: 44 lb.in (5 Nm)

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2. If removed, install the turbocharger elbow adapter, then install and tighten nuts.

   Torque: 97 lb.in (11 Nm)

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3. Install and tighten the new turbocharger mounting studs.

   Torque: 89 lb.in (10 Nm)

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4. Install the new turbocharger gasket, then install and tighten the bolt.

   Torque: 17 lb.ft (23 Nm)

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5. Install the turbocharger, then install and tighten the new turbocharger mounting nuts.

   Torque: Stage 1: Tighten in the sequence shown to: 17 lb.ft (23 Nm) | Stage 2: Re-tighten in the sequence shown to: 17 lb.ft (23 Nm)

   Fig 1: Turbocharger Tightening Sequence

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6. NOTE: Ensure that new O-rings are used.

   Install the new O-ring seals, then lubricate them with clean engine oil. Refer to: Specifications .

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7. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
   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, use brake cleaner to rinse the O-ring residue out of the turbocharger tube O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.
   1. Install the oil return tube, then install and tighten the bolts.

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

      Torque: 97 lb.in (11 Nm)

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   LHD AWD/RHD AWD 

8. Install the power transfer unit. Refer to: Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil-to-Coolant Cooler .

   LHD FWD/RHD FWD 

9. Install the bracket, then install and tighten the bolts and the nut.

   Torque: 35 lb.ft (48 Nm)

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10. Install the catalytic converter. Refer to: Catalytic Converter .

    All Vehicles 

11. Install the turbocharger heat shield, then install and tighten the turbocharger heat shield bolts and nut.

    Torque: Tighten the bolts to: 115 lb.in (13 Nm) | Tighten the nut to: 115 lb.in (13 Nm)

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12. Install the new the turbocharger coolant tube O-ring seals, lubricate with clean engine coolant. Refer to: Specifications .

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13. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • 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 bores. Inspect the area for deep scratches and gouges. Install new components if needed.
    1. Install the upper turbocharger coolant return tube first, then install the lower turbocharger supply tube and bolt. Tighten the bolt.

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

       Torque: 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

14. NOTE: Ensure that new turbocharger oil supply tube O-rings are used.

    Install the new turbocharger oil supply tube O-rings if not already installed. Lubricate the O-ring seals with clean engine oil. Refer to: Specifications .

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15. NOTE: The oil supply tube must be fully seated prior to fastener tightening.
    • NOTE: Do not use a metal brush, damage to sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to rinse the O-ring residue out of the turbocharger and engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if needed.

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

    1. Install and fully seat the turbocharger oil supply tube, install and finger tighten the bolts at this stage.

       Torque: 1 : 89 lb.in (10 Nm) | 2 : 89 lb.in (10 Nm) | 3 : 22 lb.ft (30 Nm)

    Courtesy of FORD MOTOR COMPANY

16. Connect the turbocharger control hose. Use the General Equipment: Hose Clamp Remover/Installer

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17. Install the charge air cooler intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
18. Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
19. Install the cowl panel grille. Refer to: Cowl Panel Grille .
20. Check and top off the engine oil as needed. Refer to: Specifications .
21. Fill and bleed the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .