Removal And Installation: Turbocharger: Installation

All vehicles 

1. • NOTE: This sub-step is only needed if the component was removed.

     Install a new turbocharger coolant tube O-ring seal.

   • Lubricate the new O-ring seal and the tube sealing surface with clean engine coolant. 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.

     Material

     : Brake Cleaner

   1. If removed, fit the turbocharger coolant supply tube to the turbocharger. The lower coolant supply tube goes into the turbocharger first.

   Courtesy of FORD MOTOR COMPANY

3. 1. NOTE: This sub-step is only needed if the component was removed.

      If removed, install a new turbocharger coolant tube O-ring seal. Lubricate the turbocharger coolant tube O-ring seal with clean engine coolant. Refer to: SPECIFICATIONS .

   2. Lubricate the turbocharger coolant tube rubber gasket with clean engine coolant. 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.

     Material

     : Brake Cleaner

   1. If removed, fit the turbocharger coolant return tube to the turbocharger. The lower coolant supply tube goes into the turbocharger first.
   2. If removed, install and tighten the turbocharger coolant tube bolt.

      Torque

      : 11 Nm

   Courtesy of FORD MOTOR COMPANY

5. Install and tighten the turbocharger exhaust flange studs.

   Torque

   : 40 Nm

   Courtesy of FORD MOTOR COMPANY

6. If removed install and tighten the turbocharger mounting studs.

   Torque

   : 18 Nm

   Courtesy of FORD MOTOR COMPANY

7. Install the new turbocharger gasket.

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8. NOTE: The coolant tube bracket is retained by the left lower turbocharger stud and nut.

   Install the turbocharger, attach the coolant tube bracket, then install and tighten the turbocharger mounting nuts.

   Torque

   : 53 Nm

   Courtesy of FORD MOTOR COMPANY

9. Connect the turbocharger electrical connector.

   Courtesy of FORD MOTOR COMPANY

10. Install a new turbocharger coolant tube O-ring seal. Lubricate the turbocharger coolant tube O-ring seal and rubber gasket with clean engine coolant. Refer to: SPECIFICATIONS .

    Courtesy of FORD MOTOR COMPANY

11. • 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

      : Brake Cleaner

    1. Install the outer half of the turbocharger coolant supply tube, then install and tighten the turbocharger coolant supply tube bolt.

       Torque

       : 48 Nm

    Courtesy of FORD MOTOR COMPANY

12. Install a new turbocharger coolant tube O-ring seal. Lubricate the new O-ring seal and the tube sealing surface with clean engine coolant. Refer to: SPECIFICATIONS .

    Courtesy of FORD MOTOR COMPANY

13. • 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

      : Brake Cleaner

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

       Torque

       : 11 Nm

    Courtesy of FORD MOTOR COMPANY

14. NOTE: Ensure that a new turbocharger oil return tube O-ring and gasket are used.

    Install a new turbocharger oil return tube O-ring seal and a new turbocharger oil return tube gasket if not already installed. Lubricate the new turbocharger oil return tube O-ring seal 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: The oil return tube must be fully seated prior to fastener rundown.
    • 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.
    1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

       Material

       : Brake Cleaner

       Torque

       : 11 Nm

    Courtesy of FORD MOTOR COMPANY

16. NOTE: Do not reuse the turbocharger oil filter, a new turbocharger oil filter must be used.
    NOTE: Ensure that new turbocharger oil supply tube O-rings and gaskets are used.

    Install the new turbocharger oil supply tube O-rings, gaskets and oil filter if not already installed. Lubricate the O-ring seals with clean engine oil. Refer to: Specifications .

    Courtesy of FORD MOTOR COMPANY

17. NOTE: The oil supply tube must be fully seated prior to fastener tightening.
    • 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 and engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if needed.

      Material

      : Brake Cleaner

    1. Install and fully seat the turbocharger oil supply tube, then install and tighten the bolts.

       Torque

       : 11 Nm

    Courtesy of FORD MOTOR COMPANY

    FWD (front wheel drive) vehicles 

18. Install the catalytic converter. Refer to: CATALYTIC CONVERTER .
19. Install the right front wheel and tire. Refer to: WHEEL AND TIRE Wheel and Tire (204-04 Wheels and Tires).

    AWD (all-wheel drive) vehicles 

20. Install the power transfer unit. Refer to: POWER TRANSFER UNIT .

    All vehicles 

21. Install the lower air cleaner outlet pipe, then tighten the lower air cleaner outlet pipe clamp.

    Torque

    : 5 Nm

    Courtesy of FORD MOTOR COMPANY

22. Install the charge air cooler upper inlet pipe, then tighten the clamp. Engage the charge air cooler upper intake pipe retaining clip. Attach the harness retainer to the stud bolt, then connect the turbocharger bypass valve electrical connector.

    Torque

    : 5 Nm

    Courtesy of FORD MOTOR COMPANY

23. Install the upper air cleaner outlet pipe. Refer to: AIR CLEANER OUTLET PIPE .
24. Check the engine oil level and fill as needed. Refer to: Specifications .
25. Fill the cooling system. Refer to: ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING .
26. If a new turbocharger was installed, road test the vehicle.