Disassembly And Assembly: Turbocharger: Assembly

All turbochargers 

NOTE: Install a new O-ring seal on the turbocharger oil supply standoffs.
1. If necessary, install the turbocharger oil supply standoffs.
   • Tighten to 47 Nm (35 lb-ft).
Fig 1: Locating Turbocharger Oil Supply Standoffs
Courtesy of FORD MOTOR CO.
2. Using the special tools, install the low-pressure turbocharger tube seal in the turbocharger.
Fig 2: Installing Low-Pressure Turbocharger Tube Seal In Turbocharger Using Special Tools (205-153, 303-1264)
Courtesy of FORD MOTOR CO.
3. Install a new low-pressure to high-pressure turbocharger seal and gasket.
Fig 3: Locating Low-Pressure To High-Pressure Turbocharger Seal & Gasket
Courtesy of FORD MOTOR CO.
CAUTION: The washers must be installed with the convex and concave surfaces facing towards each other. Failure to install the washers correctly may result in damage to the tool.
NOTE: Prior to installing the special tool, assemble the turbochargers by hand. Verify that the turbocharger assembly goes back together evenly.
4. Install the special tool and loosely install the nuts.
Fig 4: Identifying Special Tool (303-1269)
Courtesy of FORD MOTOR CO.
CAUTION: Do not over-tighten the nuts or damage to the special tool may occur.
NOTE: A block of wood may be used to level the turbocharger during assembly of the turbochargers.
NOTE: The turbochargers do not go flush together. Remove the tool when the gap equals the measurement taken during the disassembly.
5. Using the special tool, assemble the turbocharger assembly.
   • Tighten to 17 Nm (150 lb-in).
Fig 5: Assembling Turbocharger Assembly Using Special Tool (303-1269)
Courtesy of FORD MOTOR CO.
CAUTION: Failure to use the turbocharger lifting bracket during removal, handling or installation of the turbocharger could result in a low-pressure to high-pressure turbocharger seal failure.
6. Install the special tool and bolts.
   • Tighten to 20 Nm (177 lb-in).
Fig 6: Identifying Special Tool (303-1266) & Bolts
Courtesy of FORD MOTOR CO.
7. Position the turbocharger actuator insulator.
Fig 7: Locating Turbocharger Actuator Insulator
Courtesy of FORD MOTOR CO.
8. Install the turbocharger actuator and bolts.
   • Tighten to 19 Nm (168 lb-in).
Fig 8: Locating Turbocharger Actuator Bolts
Courtesy of FORD MOTOR CO.

Turbocharger with slip-fit linkage 

9. Position the turbocharger actuator linkage and install the nut.
   • Tighten to 8 Nm (71 lb-in).
Fig 9: Locating Turbocharger Actuator Linkage Nut
Courtesy of FORD MOTOR CO.

Turbocharger with press-fit linkage 

10. Using a C-clamp and a socket, install the turbocharger actuator linkage.
Fig 10: Installing Turbocharger Actuator Rod Using A C-Clamp & A Socket
Courtesy of FORD MOTOR CO.
11. Install the clip for the turbocharger actuator linkage.
Fig 11: Locating Clip From Turbocharger Actuator Linkage
Courtesy of FORD MOTOR CO.

All turbochargers 

NOTE: Lubricate the seal with clean engine oil prior to assembly.
12. Install the turbocharger tube.
Fig 12: Locating Turbocharger Tube
Courtesy of FORD MOTOR CO.
NOTE: Large installer shown, small installer similar.
13. Position the crossover tube in a soft-jawed vise. Using the special tool, install a new seal in each end of the turbocharger crossover tube.
Fig 13: Identifying New Seal In Turbocharger Crossover Tube
Courtesy of FORD MOTOR CO.
14. Install the turbocharger crossover tube.
Fig 14: Locating Turbocharger Crossover Tube
Courtesy of FORD MOTOR CO.