Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

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

NOTE: Failure to inspect the components for debris may result in repeat failures.

NOTE: It may be necessary to use a borescope to inspect the components.

When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace the components as needed.
- CAC and the CAC tubes
- Intake air system
- Exhaust manifolds
- EGR cooler and pipes
- Diesel Oxidation Catalyst (DOC)
- Turbocharger (on engine failure only)
NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

NOTE: Do not tighten the LH turbocharger inlet pipe clamp at this time.

Disengage the new LH turbocharger inlet pipe clamp T-bolt and loosely install the new LH turbocharger inlet pipe clamp on the LH turbocharger inlet pipe.

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Clean the turbocharger sealing surfaces and wipe the turbocharger valley clean of all oil and debris.

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Install a new turbocharger mounting gasket.

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Install a new turbocharger oil supply filter.

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NOTE: Position the turbocharger on the locating dowels while being careful not to allow the dowels to damage the sealing surfaces when installing the turbocharger.

Install the turbocharger and then install the new turbocharger mounting bolts finger tight at this stage.

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NOTE: Do not tighten the LH turbocharger inlet pipe clamp at this time.

Loosely position the LH turbocharger inlet pipe clamp over both sealing flanges.

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Tighten the new turbocharger mounting bolts in the following 2 stages and in the sequence shown.
Torque: Stage 1: 133 lb.in (15 Nm) | Stage 2: 41 lb.ft (55 Nm)

Fig 1: Turbocharger Mounting Bolts Tightening Sequence
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Install a new turbocharger coolant return tube O-ring seal and lubricate the new O-ring seal 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.

NOTE: When installing the turbocharger coolant return tube, the turbocharger coolant return tube must be fully engaged and seated into the turbocharger before the fastener is tightened.
- 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 necessary.
- Connect the turbocharger coolant return tube to the turbocharger, then install and tighten the turbocharger coolant return tube bolt.
  Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
  
  Torque: Stage 1: 106 lb.in (12 Nm) | Stage 2: 30 deg.
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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Tighten the LH turbocharger inlet pipe clamp in the following 3 stages.

Torque: Stage 1: 150 lb.in (17 Nm) | Stage 2: Loosen: 3 turn(s) | Stage 3: 159 lb.in (18 Nm)

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Install the exhaust downpipe. Refer to: Exhaust Downpipe .
Install the turbocharger heat shield, then install and tighten the turbocharger heat shield bolts.
Torque: 89 lb.in (10 Nm)

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Install the lower intake manifold. Refer to: Lower Intake Manifold .
Remove and discard the oil engine filter.. Use the General Equipment: Oil Drain Equipment

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Drain the engine oil.. Use the General Equipment: Oil Drain Equipment
Torque: 19 lb.ft (26 Nm)

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NOTE: Lubricate the engine oil filter seal with clean engine oil.

Install a new engine oil filter. Refer to: Specifications .

Torque: Stage 1: 44 lb.in (5 Nm) | Stage 2: 230 deg.

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Fill the engine with the correct engine oil for the climate. Refer to: Specifications .
Evaluate the engine cooling system. Refer to: Engine Cooling System Condition Evaluation .
Perform the cooling system pressure test. Refer to: COOLING SYSTEM PRESSURE TEST
NOTE: This step is required only when a new turbocharger is being installed.

After the new turbocharger is installed, using a diagnostic scan tool, follow the on screen instructions and perform the following:
- Reset/clear the specified function for the turbo system.
- Using the scan tool clear the continuous PCM DTC's and then reset the emissions monitors information in the PCM. Refer to Engine Controls - Diagnostic Methods - article.