Removal And Installation: Turbocharger: Installation

If removed, install the turbocharger coolant tubes. Refer to Turbocharger Coolant Return Tube . Refer to Turbocharger Coolant Supply Tube .
If removed, install and tighten the turbocharger exhaust flange studs.
Torque

: 18 lb.ft (25 Nm)

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If removed, install the heat shield, then install and tighten the bolt.
Torque

: 97 lb.in (11 Nm)

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If removed install and tighten the turbocharger mounting studs.
Torque

: 159 lb.in (18 Nm)

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Install the new turbocharger gasket.

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NOTE: The coolant tube bracket is retained by the left lower turbocharger stud and nut.

Install the turbocharger, attach the coolant tube bracket, then install and tighten the turbocharger mounting nuts.

Torque

:Stage 1: Tighten 1 and 2 to: 168 lb.in (19 Nm)

Stage 2: Tighten 3 and 4 to: 39 lb.ft (53 Nm)

Stage 3: Tighten 1 and 2 to: 39 lb.ft (53 Nm)

Fig 1: Turbocharger Mounting Nuts Tightening Sequence
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Connect the turbocharger electrical connector.

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Install a new coolant tube O-ring seal. Lubricate the O-ring seal and rubber gasket 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, 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. Install new components if needed.
  
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
1. Install the outer half of the turbocharger coolant supply tube, then install and tighten the turbocharger coolant supply tube bolt.
  Torque
  
  : 35 lb.ft (48 Nm)
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Install a new O-ring seal. Lubricate with clean engine coolant. Refer to Specifications .

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Lubricate the rubber gasket 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, 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. Install new components if needed.
  
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
1. Install the outer half of the turbocharger coolant return tube, then install and tighten the turbocharger coolant return tube bolt.
  Torque
  
  : 35 lb.ft (48 Nm)
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NOTE: Ensure that a new turbocharger oil return tube O-ring and gasket are used.

Install a new turbocharger oil return tube O-ring seal and a new turbocharger oil return tube gasket if not already installed. Lubricate the new turbocharger oil return tube O-ring seal 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 turbocharger oil return tube bolts.
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
  
  Torque
  
  : 97 lb.in (11 Nm)
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NOTE: Do not reuse the turbocharger oil filter, a new turbocharger oil filter must be used.

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

Install the new turbocharger oil supply tube O-rings, gaskets and oil filter 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 turbocharger oil supply tube, then install and tighten the bolts.
  Torque
  
  : 97 lb.in (11 Nm)
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Clean and Inspect the gasket surfaces.

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Install a new gasket.

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Install the catalytic converter, then install the new nuts finger tight at this stage.

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Tighten the catalytic converter nuts.
Torque

: 35 lb.ft (48 Nm)

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Install the battery tray. Refer to Battery Tray .
Install the upper charge air cooler inlet pipe, then tighten the clamp. Engage the inlet pipe lower retaining clip. Attach the harness retainer to the inlet pipe, then connect the turbocharger bypass valve electrical connector.
Torque

: 44 lb.in (5 Nm)

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Install the air cleaner outlet pipe. Refer to Air Cleaner Outlet Pipe .
Install the power transfer unit. Refer to Power Transfer Unit .
Check the engine oil level and fill as needed. Refer to Specifications .
Fill the cooling system. Refer to Engine Cooling System Draining, Vacuum Filling and Bleeding .
Road test the vehicle.