Removal And Installation: Turbocharger: Installation

All vehicles 

1. NOTE: This step is only needed if the component was removed.
   NOTE: Make sure that new components are installed.
   NOTE: Component(s) must be lubricated with clean engine coolant.

   Install the turbocharger coolant return tube seals. 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. Refer to: Specifications .
   • Install the turbocharger coolant return tube.

   Courtesy of FORD MOTOR COMPANY

3. NOTE: This step is only needed if the component was removed.
   NOTE: Make sure that new components are installed.
   NOTE: Component(s) must be lubricated with clean engine coolant.

   Install turbocharger coolant supply tube seals. 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. Refer to: Specifications .
   • Install the turbocharger coolant supply tube and tighten the bolt.

     Torque: 97 lb.in (11 Nm)

   Courtesy of FORD MOTOR COMPANY

5. NOTE: Make sure that new components are installed.
   NOTE: Component(s) must be lubricated with clean engine oil.

   Lubricate the turbocharger oil supply tube seals. Refer to: Specifications .

   Courtesy of FORD MOTOR COMPANY

6. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
   NOTE: Make sure that new components are installed.
   • 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. Refer to: Specifications .
   • Install the turbocharger oil supply tube and tighten the bolt.

     Torque: 97 lb.in (11 Nm)

   Courtesy of FORD MOTOR COMPANY

7. NOTE: Make sure that new components are installed.
   NOTE: The component must be installed by hand before final tightening.

   If removed, install and tighten the turbocharger mounting studs.

   Torque: 159 lb.in (18 Nm)

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8. NOTE: Make sure that new components are installed.

   Install the turbocharger gasket.

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9. NOTE: Only tighten the nuts finger tight at this stage.

   Install the turbocharger and the mounting nuts.

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10. Install the turbocharger heat shield and tighten the nuts and bolt in the given sequence.

    Torque:Nuts: 39 lb.ft (53 Nm)Bolt: 97 lb.in (11 Nm)

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11. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    NOTE: The component must be fully seated prior to fastener tightening.
    • 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. Refer to: Specifications .
    • Install the turbocharger coolant supply tube and tighten the bolt.

      Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

12. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    NOTE: The component must be fully seated prior to fastener tightening.
    • 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. Refer to: Specifications .
    • Install the turbocharger coolant return tube and tighten the bolt.

      Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

13. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    NOTE: The component must be fully seated prior to fastener tightening.
    • 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. Refer to: Specifications .
    • Install the turbocharger oil supply tube and tighten the bolt.

      Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

14. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    NOTE: Make sure that new components are installed.
    NOTE: Component(s) must be lubricated with clean engine oil.
    NOTE: The component must be fully seated prior to fastener tightening.
    • 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. Refer to: Specifications . Refer to: Specifications .
    • Install the turbocharger oil return tube.

      Torque: 97 lb.in (11 Nm)

    Courtesy of FORD MOTOR COMPANY

15. Connect the turbocharger electrical connector and attach the retainer.

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    AWD (all-wheel drive) vehicles 

16. Install the catalytic converter and tighten the clamp.

    Torque: 159 lb.in (18 Nm)

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17. Install the catalytic converter support bracket and tighten the nuts.

    Torque:1: 30 lb.ft (40 Nm)2: 35 lb.ft (48 Nm)

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18. Install the power transfer unit. Refer to: Power Transfer Unit - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler . Refer to: Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil-to-Coolant Cooler .

    FWD (front wheel drive) vehicles 

19. Install the catalytic converter. Refer to: Catalytic Converter .
20. Install the right front wheel and tire. Refer to: Wheel and Tire .

    All vehicles 

21. Install the CAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
22. Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
23. Check the engine oil level and fill as needed. Refer to: Specifications .
24. Fill the cooling system. Refer to: Specifications .