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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 690 (Fuel Charging And Controls - Turbocharger - 3.0L Power Stroke Diesel) >> Removal And Installation >> Turbocharger >> Installation

Removal And Installation: Turbocharger: Installation

WARNING: This page is about a different car, the 2021 Ford F-150. 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.

All Vehicles 

    • 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 turbocharger 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

    • Position the turbocharger through the front of the right front fender splash shield opening, back towards the transmission.

    GFD557498Courtesy of FORD MOTOR COMPANY
  2. Lubricate the turbocharger coolant tube manifold O-ring seals and rubber gaskets with clean engine coolant. Refer to: Specifications .
    GFD557499Courtesy of FORD MOTOR COMPANY
  3. NOTE: Make sure that new turbocharger to exhaust manifold stud bolts are installed.

    1. Apply high temperature nickel anti-seize lubricant to the new turbocharger to exhaust manifold stud bolt threads.

      Material

      : Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2

    2. Install and tighten the new turbocharger to exhaust manifold stud bolts.

      Torque

      : 115 lb.in (13 Nm)

    GFD557500Courtesy of FORD MOTOR COMPANY
    • 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 turbocharger 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

    • NOTE: Install the new turbocharger coolant tube manifold in the proper orientation to the turbocharger as noted during removal.
      NOTE: All of the O-rings must be fully seated before the fastener is torqued.

      Install the new turbocharger coolant tube manifold, then install and tighten the bolt.

      Torque

      : 89 lb.in (10 Nm)

    GFD557501Courtesy of FORD MOTOR COMPANY
  5. Install the exhaust manifold heat shield, then install and tighten the heat shield bolts.

    Torque

    : 97 lb.in (11 Nm)

    GFD557495Courtesy of FORD MOTOR COMPANY
  6. Lubricate the outer half of the turbocharger coolant supply tube and the O-ring seal with clean engine coolant, then install the outer half of the turbocharger coolant supply tube into turbocharger coolant tube manifold. Refer to: Specifications .
    GFD557502Courtesy of FORD MOTOR COMPANY
  7. NOTE: Make sure that a new turbocharger gasket is installed.

    Install the new turbocharger gasket.

    GFD557503Courtesy of FORD MOTOR COMPANY
  8. NOTE: Make sure that new turbocharger nuts are installed.

    Install the turbocharger, then loosely install the new turbocharger nuts.

    Material

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

    GFD557504Courtesy of FORD MOTOR COMPANY
    1. 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

    2. Install the turbocharger coolant supply tube into the engine, then install and tighten the bolt.

      Torque

      : 89 lb.in (10 Nm)

    GFD557491Courtesy of FORD MOTOR COMPANY
  10. Connect the coolant hose quick release coupling. Refer to: QUICK RELEASE COUPLING .
    GFD557490Courtesy of FORD MOTOR COMPANY
  11. Tighten the turbocharger nuts in the sequence shown in illustration.

    Material

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

    Torque

    : 18 lb.ft (24 Nm)

    Fig 1: Tightening Turbocharger Nuts In Sequence
    GFD557505Courtesy of FORD MOTOR COMPANY
  12. NOTE: Make sure the transmission jack makes contact on the outer ribs of the transmission fluid pan.

    Using a high-lift transmission jack, support the front of the transmission and the transfer case.

    Use the General Equipment: Transmission Jack

    LHD RWD 

  13. Remove the bolts, the crossmember and the transmission support insulator.
    GFD557488Courtesy of FORD MOTOR COMPANY

    LHD 4WD 

  14. Remove the bolts, the crossmember and the transmission support insulator.
    GFD557489Courtesy of FORD MOTOR COMPANY

    All Vehicles 

  15. Install the diesel particulate filter. Refer to: Diesel Particulate Filter (DPF) .
    1. Connect the turbocharger VNT actuator electrical connector.
    2. Attach the wiring harness retainers to the upper turbocharger heat shield.
    GFD557487Courtesy of FORD MOTOR COMPANY
  17. Install the charge air cooler intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
  18. Install the air cleaner outlet pipe RH. Refer to: Air Cleaner Outlet Pipe .
  19. Install the turbocharger oil supply tube. Refer to: Turbocharger Oil Supply Tube .
  20. Install the turbocharger oil return tube. Refer to: Turbocharger Oil Return Tube .
  21. Install the brake vacuum pump. Refer to: Vacuum Pump .
  22. Road test the vehicle.
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