Removal And Installation: Turbocharger: Installation

All vehicles 

1. • NOTE: This sub-step is only needed if the component was removed.

     Install a new turbocharger coolant tube O-ring seal.

   • Lubricate the new O-ring seal and the tube sealing surface with clean engine coolant. Refer to: SPECIFICATIONS .

   Courtesy of FORD MOTOR COMPANY

2. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
   NOTE: This step is only needed if the component was removed.
   • 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.

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

   1. If removed, fit the turbocharger coolant supply tube to the turbocharger. The lower coolant supply tube goes into the turbocharger first.

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3. 1. NOTE: This sub-step is only needed if the component was removed.

      If removed, install a new turbocharger coolant tube O-ring seal. Lubricate the turbocharger coolant tube O-ring seal with clean engine coolant. Refer to: SPECIFICATIONS .

   2. Lubricate the turbocharger coolant tube rubber gasket with clean engine coolant. Refer to: SPECIFICATIONS .

   Courtesy of FORD MOTOR COMPANY

4. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
   NOTE: This step is only needed if the component was removed.
   • 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.

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

   1. If removed, fit the turbocharger coolant return tube to the turbocharger. The lower coolant supply tube goes into the turbocharger first.
   2. If removed, install and tighten the turbocharger coolant tube bolt.

      Torque: 97 lb.in (11 Nm)

   Courtesy of FORD MOTOR COMPANY

5. Install and tighten the turbocharger exhaust flange studs.

   Torque: 30 lb.ft (40 Nm)

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6. If removed install and tighten the turbocharger mounting studs.

   Torque: 159 lb.in (18 Nm)

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7. Install the new turbocharger gasket.

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8. 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: 39 lb.ft (53 Nm)

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9. Connect the turbocharger electrical connector.

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10. Install a new turbocharger coolant tube O-ring seal. Lubricate the turbocharger coolant tube O-ring seal and rubber gasket with clean engine coolant. Refer to: SPECIFICATIONS .

    Courtesy of FORD MOTOR COMPANY

11. • 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)

    Courtesy of FORD MOTOR COMPANY

12. Install a new turbocharger coolant tube O-ring seal. Lubricate the new O-ring seal and the tube sealing surface with clean engine coolant. Refer to: SPECIFICATIONS .

    Courtesy of FORD MOTOR COMPANY

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, 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)

    Courtesy of FORD MOTOR COMPANY

14. 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

    Courtesy of FORD MOTOR COMPANY

15. 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)

    Courtesy of FORD MOTOR COMPANY

16. 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

    Courtesy of FORD MOTOR COMPANY

17. 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)

    Courtesy of FORD MOTOR COMPANY

    AWD (all-wheel drive) vehicles 

18. Clean and Inspect the gasket surfaces.

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19. Install a new gasket.

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

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21. Tighten the catalytic converter nuts.

    Torque: 30 lb.ft (40 Nm)

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22. Install the battery tray. Refer to: BATTERY TRAY .

    FWD (front wheel drive) vehicles 

23. Install the catalytic converter. Refer to: CATALYTIC CONVERTER

    All vehicles 

24. Install the lower air cleaner outlet pipe, then tighten the lower air cleaner outlet pipe clamp.

    Torque: 44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

25. Install the charge air cooler upper inlet pipe, then tighten the clamp. Engage the charge air cooler upper intake pipe retaining clip. Attach the harness retainer to the stud bolt, then connect the turbocharger bypass valve electrical connector.

    Torque: 44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

26. Install the upper air cleaner outlet pipe. Refer to: AIR CLEANER OUTLET PIPE .

    FWD (front wheel drive) vehicles 

27. Install the right front wheel and tire. Refer to: REMOVAL AND INSTALLATION .

    AWD (all-wheel drive) vehicles 

28. Install the power transfer unit. Refer to: REMOVAL AND INSTALLATION

    All vehicles 

29. Check the engine oil level and fill as needed. Refer to: Specifications
30. Fill the cooling system. Refer to: ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING .