Removal And Installation: Turbocharger: Installation

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

: 97 lb.in (11 Nm)

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Install and tighten the new turbocharger mounting studs.
Torque

: 89 lb.in (10 Nm)

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

: 17 lb.ft (23 Nm)

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

:Stage 1: Tighten in the sequence shown in illustration to: 17 lb.ft (23 Nm)

Stage 2: Re-tighten in the sequence shown in illustration to: 17 lb.ft (23 Nm)

Fig 1: Turbocharger Mounting Nuts Tightening Sequence
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NOTE: Ensure that new O-rings are used.

Install the new O-rings, if already not installed, then lubricate them with clean engine oil. Refer to Specifications .

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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 turbocharger 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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Install the power transfer unit. Refer to Power Transfer Unit .
Install the turbocharger heat shield, then install and tighten the 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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Install the new the O-ring seals, lubricate with clean engine coolant. Refer to Specifications .

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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)
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NOTE: A new turbocharger oil supply tube filter must be installed. Failure to install a new filter will cause turbocharger failure.

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

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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 new turbocharger oil supply tube, install and finger tighten the bolts at this stage.
  Torque
  
  : Tighten 1 to: 89 lb.in (10 Nm)
  
  Tighten 2 to: 89 lb.in (10 Nm)
  
  Tighten 3 to: 22 lb.ft (30 Nm)
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Connect the turbocharger control hose. Use the General Equipment: Hose Clamp Remover/Installer

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Install the charge air cooler intake pipe. Refer to Charge Air Cooler (CAC) Intake Pipe .
Install the air cleaner outlet pipe. Refer to Air Cleaner Outlet Pipe .
Check and top off the engine oil as needed. Refer to Specifications .
Fill and bleed the cooling system. Refer to Engine Cooling System Draining, Vacuum Filling and Bleeding .
Road test the vehicle.