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Home >> Mercedes Benz >> 2025 >> eSprinter Base, _NA_ >> Repair and Diagnosis >> External Pages >> Different car >> Section 2399 (Fuel Charging System 6.4L 99R Diesel Engine - Turbocharger -- F250-F550 Super Duty) >> Removal And Installation >> Turbocharger - Body On >> Installation

Turbocharger - Body On: 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.
    NOTE: Lubricate the low-pressure turbocharger oil drain tube with clean engine oil prior to installing.
    NOTE: Install the low-pressure turbocharger drain tube with the taper side down.
  1. Install the low-pressure turbocharger drain tube in the turbocharger.
    2. NOTE: Install 2 new O-rings seals and lubricate with clean engine oil prior to installing.
  2. Install the turbocharger high-pressure oil drain tube.
    3. 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 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.
    NOTE: Make sure the turbocharger is positioned under the high-pressure fuel pump heat shield on the right side.
    NOTE: Install a new gasket for the RH turbocharger inlet pipe at the RH exhaust manifold prior to installing the turbocharger assembly.
  3. With the help of an assistant, using the heavy duty lifting crane, install the turbocharger assembly.
    4. NOTE: After removing the special tool, the top bolt holes remain open on the turbocharger.
  4. Remove the special tool.
  5. Install the 2 turbocharger hold downs and bolts.
    • Tighten to 201 Nm (148 lb-ft).
  6. Connect the EGR valve electrical connector.
    7. Fig 1: Locating EGR Valve Electrical Connector
    GF0048995Courtesy of FORD MOTOR CO.
  7. Install the oil filter base gasket and O-ring seal.
    • Apply clean engine oil to the oil filter base gasket and O-ring seal.
    8. Fig 2: Locating O-Ring Seal & Gasket
    GF0048673Courtesy of FORD MOTOR CO.
  8. Install the oil filter return tube assembly and screw.
    • On new oil return tubes, tighten to 7 Nm (62 lb-in).
    • On used oil return tubes, tighten to 5 Nm (44 lb-in).
    9. Fig 3: Locating Oil Filter Return Tub Screw
    GF0048672Courtesy of FORD MOTOR CO.
  9. Install the oil filter housing and 4 Torx bolts.
    • Tighten to 22 Nm (16 lb-ft).
    10. Fig 4: Locating Oil Filter Housing Bolts
    GF0048671Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal on the oil filter cap and apply clean engine oil.
  10. Install a new oil filter element and the oil filter cap.
    • Tighten to 25 Nm (18 lb-ft).
    11. Fig 5: Locating Oil Filter Cap & Oil Filter Element
    GF0048670Courtesy of FORD MOTOR CO.
  11. Connect the fuel injection pump supply tube at the fuel filter module.
    12. Fig 6: Releasing Fuel Supply Hose Connector Using A Commercially Available Tool
    GF0048667Courtesy of FORD MOTOR CO.
  12. Install the bolt for the engine wiring harness.
    • Tighten to 8 Nm (71 lb-in).
    13. Fig 7: Locating Engine Wiring Harness Bolt
    GF0048994Courtesy of FORD MOTOR CO.
  13. Position the front fuel cooler bracket. Install the bolts for the turbocharger crossover tube.
    • Tighten to 31 Nm (23 lb-ft).
    14. Fig 8: Locating Turbocharger Crossover Tube Bolts
    GF0048678Courtesy of FORD MOTOR CO.
  14. Position back the oil level indicator and tube and install the nut.
    • Tighten to 31 Nm (23 lb-ft).
    15. Fig 9: Locating Retaining Nut From Oil Level Indicator Tube
    GF0048597Courtesy of FORD MOTOR CO.
    CAUTION: Use only 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 fuel system.
  15. Install fuel cooler-to-fuel filter module tube, new copper sealing washer and the banjo bolt.
    • Tighten to 38 Nm (28 lb-ft).
    16. Fig 10: Identifying Banjo Bolt, Copper Sealing Washer & Fuel Cooler To Fuel Filter Module Tube
    GF0048993Courtesy of FORD MOTOR CO.
  16. Install the fuel filter element and cover.
    • Tighten to 27 Nm (20 lb-ft).
    17. Fig 11: Locating Fuel Filter Element & Cover
    GF0048992Courtesy of FORD MOTOR CO.
  17. Install the CAC tube flex coupling and clamps.
    • Tighten the engine clamp to 12 Nm (106 lb-in).
    • Tighten the tube clamp to 8 Nm (71 lb-in).
    18. Fig 12: Locating CAC Tube Flex Coupling & Clamps
    GF0048991Courtesy of FORD MOTOR CO.
  18. Install the 2 studs for the RH turbocharger inlet pipe.
    • Tighten to 18 Nm (159 lb-in).
    19. Fig 13: Locating RH Turbocharger Inlet Pipe-To-Exhaust Manifold Studs
    GF0048551Courtesy of FORD MOTOR CO.
    CAUTION: Do not bend or twist the turbocharger inlet pipe or damage to the turbocharger inlet pipe may occur.
    NOTE: To aid in installation, replace the top stud with bolt part number W302649.
    NOTE: It will be necessary to position the OC-EGR pipe as needed.
  19. Position the LH turbocharger inlet pipe in the vehicle. Install the gasket and 2 studs for the LH turbocharger inlet pipe. Loosely install the bolt.
    • Tighten the studs to 18 Nm (159 lb-in).
    20. Fig 14: Locating LH Turbocharger Inlet Pipe-To-Exhaust Manifold Gasket & Lower Studs
    GF0048689Courtesy of FORD MOTOR CO.
  20. Install the turbocharger inlet pipe gaskets, bracket and loosely install the 6 new bolts.
    • Tighten the top 4 bolts to 25 Nm (18 lb-ft).
    21. Fig 15: Locating Exhaust Manifolds-To-Turbocharger Inlet Pipe Joints
    GF0048682Courtesy of FORD MOTOR CO.
    CAUTION: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
    NOTE: To complete this step, it will be necessary to use the following tools:
    • A 3/8-in drive torque wrench that is 241.3 mm (9.5 in) or 368.3 mm (14.5 in) from center of the handle to the center of the square drive.
    • One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
    • A 12-mm Allen socket (to drive the Half-moon wrench).
    NOTE: To obtain the required torque value of 25 Nm (18 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
  21. Tighten the turbocharger inlet pipes-to-turbocharger bottom 2 bolts.
    • Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
    22. Fig 16: Tightening Turbocharger Inlet Pipes-To-Turbocharger Bottom 2 Bolts
    GF0048884Courtesy of FORD MOTOR CO.
    Fig 17: Torque Wrench Setting Chart
    GF0048885Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  22. Install the 5 lower turbocharger inlet pipe nuts.
    • Tighten to 31 Nm (23 lb-ft).
    23. Fig 18: Locating LH Turbocharger Inlet Pipe-To-Exhaust Manifold Nuts
    GF0048688Courtesy of FORD MOTOR CO.
    CAUTION: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
    NOTE: To complete this step, it will be necessary to use the following tools:
    • A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
    • One of the 10-mm/12-mm Half-moon wrenches listed in the following chart.
    • A 12-mm Allen socket (to drive the Half-moon wrench).
    NOTE: To obtain the required torque value of 31 Nm (23 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
  23. Tighten the LH turbocharger inlet pipe-to-LH exhaust manifold bolt.
    • Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
    24. Fig 19: Locating LH Turbocharger Inlet Pipe-To-LH Exhaust Manifold Bolt
    GF0048886Courtesy of FORD MOTOR CO.
    Fig 20: Torque Wrench Setting Chart
    GF0048887Courtesy of FORD MOTOR CO.
  24. Install the new gasket and clamp for the exhaust downpipe.
    • Tighten to 15 Nm (133 lb-in).
    25. Fig 21: Locating Exhaust Downpipe Clamp
    GF0048544Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.
  25. Position the EGR-OC pipe and loosely install the new bracket bolts. Install a gasket and loosely install the new bolts.
    26. Fig 22: Locating EGR-OC-to-Bracket Bolts
    GF0048548Courtesy of FORD MOTOR CO.
  26. Tighten the bolts for the exhaust downpipe at the OC.
    • Tighten to 40 Nm (30 lb-ft).
    27. Fig 23: Locating Exhaust Downpipe-To-Oxidation Catalytic Converter (OC) Pipe Bolts
    GF0048543Courtesy of FORD MOTOR CO.
    CAUTION: Failure to install and correctly tighten the exhaust gas recirculation (EGR)-oxidation catalytic converter (OC) pipe support bolts will result in damage to the horizontal EGR cooler and possible engine damage.
  27. Install the bracket, washers and loosely install the new bolts for the EGR-OC pipe bracket.
    28. Fig 24: Locating EGR-OC Pipe Bracket-To-Cylinder Head Bracket Bolt & Washer
    GF0048546Courtesy of FORD MOTOR CO.
  28. Install the gasket and the new bolts for the EGR-OC pipe at the EGR cooler.
    • Tighten to 31 Nm (23 lb-ft).
    29. Fig 25: Locating EGR-OC-To-EGR Cooler Bolts
    GF0048547Courtesy of FORD MOTOR CO.
  29. Tighten the EGR-OC pipe bolts at the RH turbocharger inlet pipe.
    • Tighten to 31 Nm (23 lb-ft).
    30. Fig 26: Tightening RH Turbocharger Inlet Pipe-To-EGR-OC Bolts
    GF0048563Courtesy of FORD MOTOR CO.
  30. Tighten the bolts for the EGR-OC pipe bracket at the turbocharger.
    • Tighten to 31 Nm (23 lb-ft).
    31. Fig 27: Tightening Bolts For EGR-OC Pipe Bracket At Turbocharger
    GF0048564Courtesy of FORD MOTOR CO.
    CAUTION: Failure to install and correctly tighten the exhaust gas recirculation (EGR)-oxidation catalytic converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
  31. Tighten the bolt for the EGR-OC pipe bracket.
    • Tighten to 31 Nm (23 lb-ft).
    32. Fig 28: Tightening EGR-OC Bracket-To-Cylinder Head Bracket Bolt
    GF0048565Courtesy of FORD MOTOR CO.
    CAUTION: Failure to install and correctly tighten the exhaust gas recirculation (EGR)-oxidation catalytic converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
    CAUTION: Due to limited access, one of the specific Half-moon wrenches and other tools described must be used to correctly tighten the fasteners in this step. Failure to follow this instruction may result in engine failure.
    NOTE: To complete this step, it will be necessary to use the following tools:
    • A 3/8-in drive torque wrench that is 368.3 mm (14.5 in) or 381.0 mm (15.0 in) from the center of the handle to the center of the square drive.
    • One of the 11-mm/13-mm Half-moon wrenches listed in the following chart.
    • A 11-mm Allen socket (to drive the Half-moon wrench).
    NOTE: To obtain the required torque value of 63 Nm (46 lb-ft), it will be crucial to orient the Half-moon wrench in the direction shown and 180 degrees (straight out) from the torque wrench. The torque wrench must be set to the value specified in the following chart for the Half-moon wrench and torque wrench length being used.
  32. Tighten the EGR-OC pipe bracket-to-LH cylinder head bolt.
    • Refer to the following chart for torque wrench setting, based on the specific Half-moon wrench and torque wrench length being used.
    33. Fig 29: Locating EGR-OC Pipe Bracket-To-LH Cylinder Head Bolt
    GF0048566Courtesy of FORD MOTOR CO.
    Fig 30: Torque Wrench Setting Chart
    GF0048888Courtesy of FORD MOTOR CO.
  33. Install the EP sensor tube fitting into the EGR-OC pipe.
    • Tighten to 27 Nm (20 lb-ft).
    34. Fig 31: Locating EP Tube Assembly
    GF0048681Courtesy of FORD MOTOR CO.
  34. Connect the EP sensor tube to the EGR-OC pipe.
    • Tighten to 20 Nm (177 lb-in).
    35. Fig 32: Locating Exhaust Pressure (EP) Sensor Tube From EGR-OC Pipe
    GF0048545Courtesy of FORD MOTOR CO.
  35. If equipped, position back the front drive shaft and install the straps and bolts.
    • Tighten to 35 Nm (26 lb-ft).
    36. Fig 33: Locating Front Drive Shaft & Bolts
    GF0048990Courtesy of FORD MOTOR CO.
  36. Install the EGRT sensor into the RH turbocharger inlet pipe.
    • Tighten to 44 Nm (32 lb-ft).
    37. Fig 34: Locating Exhaust Gas Recirculation Temperature (EGRT) Sensor From RH Turbocharger Inlet Pipe
    GF0048549Courtesy of FORD MOTOR CO.
  37. Install the RH splash shield. For additional information, refer to FRONT END BODY PANELS article.
  38. Connect the turbocharger actuator electrical connector and pin-type retainer.
    39. Fig 35: Locating Turbocharger Actuator Electrical Connector & Push Pin Retainer
    GF0048677Courtesy of FORD MOTOR CO.
  39. Position the fuel cooler bracket.
    40. Fig 36: Locating Fuel Cooler Bracket
    GF0048676Courtesy of FORD MOTOR CO.
  40. Position back the fuel cooler, fuel cooling system expansion tank and turbocharger actuator cooler. Install the bolts for the turbocharger actuator cooler. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Finger tighten the bolts.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    41. Fig 37: Tightening Turbocharger Actuator Cooler Bolts In Sequence
    GF0048889Courtesy of FORD MOTOR CO.
  41. Install the 2 nuts for the fuel cooler.
    • Tighten to 19 Nm (168 lb-in).
    42. Fig 38: Locating Retaining Nuts For Fuel Cooler
    GF0048289Courtesy of FORD MOTOR CO.
    NOTE: It may be necessary to loosen the front bolts of the turbocharger crossover in order to get correct alignment of the holes for the fuel cooler.
  42. Install the 2 stud bolts for the fuel cooler.
    • Tighten to 25 Nm (18 lb-ft).
    43. Fig 39: Locating Studs For Fuel Cooler
    GF0048288Courtesy of FORD MOTOR CO.
  43. Install the 2 bolts for the fuel cooler.
    • Tighten to 9 Nm (80 lb-in).
    44. Fig 40: Locating Fuel Cooler Mounting Bolts
    GF0048287Courtesy of FORD MOTOR CO.
  44. Install the 3 bolts for the fuel cooling system expansion tank.
    • Tighten to 9 Nm (80 lb-in).
    45. Fig 41: Locating Bolts From Fuel Cooler & Coolant Expansion Tank
    GF0048290Courtesy of FORD MOTOR CO.
    CAUTION: Use only 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 fuel system.
    CAUTION: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.
  45. Install the new sealing washers and banjo bolts at the fuel cooler.
    • Tighten to 25 Nm (18 lb-ft).
    46. Fig 42: Locating Banjo Fittings & Sealing Washers From Fuel Cooler
    GF0048285Courtesy of FORD MOTOR CO.
  46. Position the turbocharger heat shield and install the bolt.
    • Tighten to 11 Nm (97 lb-in).
    47. Fig 43: Locating Turbocharger Heat Shield Bolts
    GF0048674Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal and apply clean engine oil.
  47. Position the turbocharger oil supply tube and install the bolt.
    • Tighten to 13 Nm (115 lb-in).
    48. Fig 44: Locating Turbocharger Oil Supply Tube Bolt
    GF0048669Courtesy of FORD MOTOR CO.
  48. Pre-lubricate the oil inlet holes of the turbocharger assembly with clean engine oil and spin the compressor wheel several times to coat the bearings with oil.
    49. CAUTION: Use only 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.
    CAUTION: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
    NOTE: Use a back-up wrench to prevent the fittings from turning.
  49. Install 2 new copper sealing washers and the turbocharger oil supply tube banjo bolts.
    • Tighten to 38 Nm (28 lb-ft).
    • Verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
    50. Fig 45: Locating Turbocharger Oil Supply Tube Banjo Fitting Bolts & Copper Sealing Washers
    GF0048668Courtesy of FORD MOTOR CO.
  50. Position the auxiliary air intake hose in the vehicle.
    51. Fig 46: Locating Auxiliary Air Intake From Cowl
    GF0048542Courtesy of FORD MOTOR CO.
  51. Install the air cleaner assembly and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  52. Install the degas bottle. For additional information, refer to ENGINE COOLING article.
  53. Bleed the low pressure fuel system. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
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