Removal And Installation: Turbocharger: Installation

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

If removed install and then tighten the turbocharger exhaust flange studbolts.
Torque: 18 lb.ft (25 Nm)

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If removed install and then tighten the turbocharger mounting studs.
Torque: 150 lb.in (17 Nm)

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Install the new turbocharger gasket.

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Install the turbocharger, then install and tighten the lower turbocharger mounting nuts.
Torque: 1 : 37 lb.ft (50 Nm) 2 : 37 lb.ft (50 Nm)

Fig 1: TC Lower Mounting Nuts Tightening Specifications
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Position and attach the turbocharger control valve vacuum tube retainers. Connect the cylinder head temperature electrical connector and then attach the cylinder head temperature wiring harness retainer.

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Install a new turbocharger oil return tube O-ring seal and a new turbocharger oil return tube gasket. Lubricate the new turbocharger oil return tube O-ring seal 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: The oil return tube must be fully seated prior to fastener rundown.

Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

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

Torque: 89 lb.in (10 Nm)

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

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NOTE: Do not reuse the turbocharger oil filter, a new turbocharger oil filter must be installed.

Install the new turbocharger oil filter.

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Install a new turbocharger oil supply tube O-ring seal and the new turbocharger oil supply tube sealing washers. Lubricate the new turbocharger oil supply tube O-ring seal 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 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: The oil supply tube must be fully seated prior to fastener tightening.

Install the turbocharger oil supply tube and the turbocharger oil supply tube retaining bolts finger tight at this stage.

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

Torque: Bolt : 89 lb.in (10 Nm) Banjo bolt : 18 lb.ft (25 Nm) Tighten the Banjo bolt an additional : 50°

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NOTE: Install the turbocharger heat shield, the upper turbocharger mounting nuts and the lower turbocharger heat shield retaining bolt finger tight at this stage.
1. Tighten the upper turbocharger mounting nuts.
  Torque: 37 lb.ft (50 Nm)
2. Tighten the lower turbocharger heat shield retaining bolt.
  Torque: 89 lb.in (10 Nm)
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Install the new turbocharger coolant tube sealing washers. Install the new turbocharger coolant tube O-ring seals and lubricate with clean engine coolant. 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.
1. Hand start the turbocharger cooling tube-to-block bolt at this stage.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
2. NOTE: Lubricate the turbocharger cooling tube O-ring seals with clean engine coolant.
  
  Fit the O-ring end of the turbocharger coolant tubes to the turbocharger. The lower coolant inlet tube goes into the turbocharger first.
3. Install and tighten the turbocharger coolant tube-to-turbocharger bolt.
  Torque: 89 lb.in (10 Nm)
4. Tighten the turbocharger coolant tube-to-block bolt.
  Torque: 27 lb.ft (37 Nm)
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Install the new turbocharger gasket.

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Install the catalytic converter, then install and tighten the catalytic converter retaining nuts.
Torque: 35 lb.ft (48 Nm)

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Install the battery tray. Refer to: Battery Tray .
Install and tighten the catalytic converter bracket retaining bolts.
Torque: 35 lb.ft (48 Nm)

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Install and tighten the exhaust isolator bracket bolts.
Torque: 18 lb.ft (25 Nm)

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Install the Charge Air Cooler (CAC) Intake Pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
- Install the stone guard and the retainers.
- Install the underbody shield and the retainers.
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Install the upper and lower Air Cleaner Outlet Pipes. Refer to: Air Cleaner Outlet Pipe .
1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.
  
  Lubricate each grommet with silicone grease.
  
  Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)
2. If equipped, position the engine appearance cover onto engine with the grommets aligned with the studs.
3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.
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Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Check and top off the engine oil as needed. Refer to: Specifications .
Check for leaks.