Turbocharger RH: Installation

All vehicles 

1. If removed install and tighten the turbocharger exhaust flange studbolts.

   Torque

   : 18 lb.ft (25 Nm)

   Courtesy of FORD MOTOR COMPANY

2. NOTE: Install short end of stud into engine cylinder head.

   If removed install and tighten the turbocharger mounting studs.

   Torque

   : 106 lb.in (12 Nm)

   Courtesy of FORD MOTOR COMPANY

3. Install the new turbocharger gasket.

   Courtesy of FORD MOTOR COMPANY

4. Install a new turbocharger coolant supply tube O-ring seal and lubricate with clean engine coolant. Refer to: Specifications

   Courtesy of FORD MOTOR COMPANY

5. 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 tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.

     Material

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

   • Install the turbocharger, then loosely install the turbocharger retainers. Install the turbocharger coolant supply tube to the engine block while installing the turbocharger.
   • Tighten the turbocharger retainers in the following sequence.

     Torque

     : Tighten 1 to: : 44 lb.ft (60 Nm) Tighten 2 to: : 44 lb.ft (60 Nm) Tighten 3 to: : 27 lb.ft (37 Nm) Re-tighten 1 to: : 44 lb.ft (60 Nm) Re-tighten 2 to: : 44 lb.ft (60 Nm) Re-tighten 3 to: : 27 lb.ft (37 Nm)

   Courtesy of FORD MOTOR COMPANY

6. Install and tighten the turbocharger coolant supply tube bolt.

   Torque

   : 18 lb.ft (24 Nm)

   Courtesy of FORD MOTOR COMPANY

7. Install the new turbocharger oil return tube to engine gasket.

   Courtesy of FORD MOTOR COMPANY

8. Install a new turbocharger oil return tube O-ring seal, then lubricate with clean engine oil. Refer to: Specifications

   Courtesy of FORD MOTOR COMPANY

9. 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 bore. Inspect the area for deep scratches and gouges. Install new components as needed.

     Material

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

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

      Torque

      : 89 lb.in (10 Nm)

   Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

11. Install a new turbocharger coolant return tube O-ring seal, then lubricate the new O-ring seal with clean engine coolant. Refer to: Specifications

    Courtesy of FORD MOTOR COMPANY

12. 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 bore. Inspect the area for deep scratches and gouges. Install new components as needed.

      Material

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

    1. Install the turbocharger coolant return tube, then install and tighten the turbocharger coolant return tube bolt.

       Torque

       : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

13. Install the catalytic converter RH. Refer to: Catalytic Converter RH
14. Install the new turbocharger oil supply tube O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the O-ring seals 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: When installing the turbocharger oil supply tube into the engine block, use care not to damage the new turbocharger oil supply tube oil filter.
    • 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 turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components as needed.
    1. Install the turbocharger oil supply tube, then install and tighten the turbocharger oil supply tube bolts.

       Material

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

       Torque

       : 89 lb.in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

16. Install the right lower charge air cooler intake pipe, then tighten the clamps.

    Torque

    : 44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

17. Install the upper and lower air cleaner outlet pipe RH. Refer to: Air Cleaner Outlet Pipe RH

    AWD (all-wheel drive) 

18. Install the power transfer unit. Refer to: Power Transfer Unit

    All vehicles 

19. Install the underbody shields and the retainers.
20. Install the right front wheel and tire. Refer to: Wheel and Tire

    Courtesy of FORD MOTOR COMPANY

21. If equipped, install the engine appearance cover, then install and tighten the engine appearance cover retainers.

    Torque

    : Tighten the nut to: : 42 lb.in (4.8 Nm) Tighten the bolt to: : 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

22. Check and top off the engine oil level as needed. Refer to: Specifications
23. Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding