Turbocharger RH: Installation

WARNING: This page is about a different variant/trim than selected.

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

Lubricate the O-ring with clean engine oil. Refer to: Specifications .

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Install and tighten the turbocharger fitting and oil filter assembly.
Torque: 24 lb.ft (32 Nm)

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Install the new O-ring seal, then lubricate with clean engine oil. Refer to: Specifications .

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- Lubricate the cylinder block bore with clean engine oil.
1. Install the turbocharger oil tube assembly, then install and tighten the lower bolt in the following 2 stages. Refer to: Specifications .
  Torque:
  
  Stage 1: 71 lb.in (8 Nm)
  
  Stage 2: 30°
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Install the new the turbocharger exhaust flange gasket.

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- Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange studbolt threads prior to installation.
1. Install the turbocharger exhaust flange, then install and tighten the new studbolts.
  Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
  
  Torque: 30 lb.ft (40 Nm)
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Install the new turbocharger gasket.

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Inspect the fitting and replace as needed.
Torque: 159 lb.in (18 Nm)

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Connect the turbocharger coolant tube.

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Inspect the fitting and replace as needed.
Torque: 37 lb.ft (50 Nm)

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Install the new turbocharger mounting bolts, install the turbocharger coolant supply tube to the block fitting while installing the turbocharger.
Torque: 24 lb.ft (32 Nm)

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Install the new upper turbocharger oil tube assembly gasket.

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- Install the turbocharger oil tube assembly upper bolts finger tight.
1. Tighten the outer bolt.
  Torque: 44 lb.in (5 Nm)
2. Tighten the inner bolt in the following 2 stages.
  Torque:
  
  Stage 1: 89 lb.in (10 Nm)
  
  Stage 2: 30°
3. Tighten the outer bolt in the following 2 stages.
  Torque:
  
  Stage 1: 89 lb.in (10 Nm)
  
  Stage 2: 30°
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Install and tighten the bolt for the turbocharger tubes.
Torque:

Stage 1: 71 lb.in (8 Nm)

Stage 2: 30°

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Connect the turbocharger control hose.

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Inspect the turbocharger coolant return tube fitting and replace as needed.
Torque: 159 lb.in (18 Nm)

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Install and connect the turbocharger coolant return tube.

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- Install the dual catalytic converter Y-Pipe with a new left gasket. Install the right and the left fasteners hand tight.
- Evenly tighten the new left catalytic converter flange nuts.
  Torque: 30 lb.ft (40 Nm)
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Evenly tighten the new right catalytic converter flange nuts.
Torque: 30 lb.ft (40 Nm)

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Install the air conditioning compressor, then install the bolts and wiring harness bracket the finger tight. Tighten the bolts in the sequence shown in illustration.
Torque: 18 lb.ft (25 Nm)

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Connect the electrical connectors, then attach the harness retainer.

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Install the air conditioning (A/C) compressor belt.
Install the starter motor. Refer to: Starter Motor .
Install the engine crossmember. Refer to: Engine Crossmember .
Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Start and check the exhaust system for leaks.