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Turbocharger - Body Off: Installation

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. If removed, install the special tool.
    • Tighten to 20 Nm (177 lb-in).
    2. Fig 1: Identifying Special Tool (303-1266)
    GF0048988Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the low-pressure oil drain tube with clean engine oil prior to installing.
    NOTE: Install the low-pressure drain tube with the taper side down.
  2. Install the low-pressure turbocharger oil drain tube in the turbocharger.
    3. NOTE: Install 2 new O-ring seals and lubricate with clean engine oil prior to installing the tube.
  3. Install the turbocharger high-pressure oil drain tube.
    4. 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.
    CAUTION: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.
  4. Using the special tool, install the turbocharger assembly.
    5. NOTE: After removing the special tool, the top bolt holes remain open on the turbocharger.
  5. Remove the special tool.
  6. Install the 2 turbocharger hold downs and the bolts.
    • Tighten to 201 Nm (148 lb-ft).
  7. Position the turbocharger heat shield and install the 5 bolts.
    • Tighten to 11 Nm (97 lb-in).
  8. Position the front fuel cooler bracket. Install the 4 bolts for the turbocharger crossover tube.
    • Tighten to 31 Nm (23 lb-ft).
  9. Connect the turbocharger actuator electrical connector and pin-type retainer.
    10. NOTE: Install a new O-ring seal and apply clean engine oil.
  10. Position the turbocharger oil supply tube and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
  11. Pre-lubricate the oil inlet holes of the turbocharger assembly with clean oil and spin the compressor wheel several times to coat the bearings with oil.
    12. CAUTION: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
    NOTE: Use a back-up wrench to prevent the fittings from turning.
  12. Install 2 new copper sealing washers and the oil supply tube banjo fittings on the turbocharger oil supply fittings.
    • Tighten to 38 Nm (28 lb-ft).
    • Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
  13. Install the air cleaner outlet tube and tighten the clamp.
    • Tighten to 5 Nm (44 lb-in).
    14. NOTE: Install a new clamp prior to connecting the hose.
  14. Connect the air cleaner outlet tube-to-crankcase vent oil separator hose to the vent oil separator and tighten the clamp.
  15. Install the turbocharger inlet pipes. Carry out the Exhaust Gas Recirculation (EGR) Oxidation Catalytic Converter (OC) and Turbocharger Inlet Pipes - 6.4L Diesel, Body Off procedure. For additional information, refer to EXHAUST SYSTEM article.
  16. Install the body. For additional information, refer to FULL FRAME AND BODY MOUNTING article.
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