Turbocharger LH: Installation

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

If the flange was removed, install the new the turbocharger exhaust flange gasket.

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1. If removed, apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange studbolt threads prior to installation of the turbocharger exhaust flange.
  Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
2. If removed, install and tighten the turbocharger exhaust flange and the turbocharger exhaust flange studbolts.
  Torque: 30 lb.ft (40 Nm)
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Install the new turbocharger gasket by pressing the gasket into the turbocharger flange groove evenly until at least 50% of the gasket is within the groove.

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If removed, install the turbocharger coolant supply tubes. Refer to: Turbocharger Coolant Return Tube LH . Refer to: Turbocharger Coolant Supply Tube LH .
NOTE: If the 2 piece turbocharger cooling tubes are separated or the rubber gasket is leaking, then the rubber gasket must be replaced.
1. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
  
  If the 2 piece turbocharger cooling tube was separated, then remove and discard the rubber gasket. Inspect and clean the turbocharger cooling tube sealing surfaces, install new components if necessary.
  
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
2. If the 2 piece turbocharger cooling tube was separated, then install the turbocharger cooling tube rubber gasket. After installing the new rubber gasket, lubricate with clean engine coolant. Refer to: Specifications .
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Install the new turbocharger coolant supply tube and the new turbocharger coolant return tube O-ring seals. Lubricate the new O-ring seal with clean engine coolant. Refer to: Specifications .

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NOTE: Install the coolant tubes with the turbocharger.
1. 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 tube to engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if necessary.
2. NOTE: Some models may be equipped with hex head bolts.
  
  Install the turbocharger, then install and tighten the turbocharger retainers as indicated in the following 2 stages.
  
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
  
  Torque:Stage 1: Tighten 1-3 in the sequence shown to : 24 lb.ft (32 Nm)| Stage 2: Re-tighten 1 to : 24 lb.ft (32 Nm)
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Install and tighten the turbocharger coolant return tube bolt.
Torque:Stage 1: Tighten to : 89 lb.in (10 Nm)| Stage 2: Tighten an additional : 30 deg.

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Attach the fuel tubes to the retainers.

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Install and tighten the turbocharger coolant supply tube bolt.
Torque:Stage 1: Tighten to : 89 lb.in (10 Nm) | Stage 2: 30 deg.

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Install and evenly tighten the new left turbocharger exhaust flange nuts.
Torque: 30 lb.ft (40 Nm)

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Connect the turbocharger wastegate electrical connector.

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If equipped, install the engine front undershield. Refer to: Engine Front Undershield .
Install the turbocharger oil return tube LH. Refer to: Turbocharger Oil Return Tube LH .
Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Start and check for leaks.