Removal and Installation - Turbocharger

Materials

Removal

NOTICE: Turbocharger compressor blades can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, make sure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

NOTICE: Pay special attention to the sealing surfaces of the oil supply, oil return and coolant tube ports on turbocharged engines. The sealing ports must be completely clean and free of sealant residue. Do not damage the sealing surface or tubes to ensure there are no leaks and no repeat repairs.

All vehicles

1. Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling — 2 L EcoBoost (177 kW/240 L PS) — MI4, General Procedures).

All-Wheel Drive (AWD) Vehicles

2. Remove the power transfer unit.
   Refer to: Power Transfer Unit — Vehicles with: Power Transfer Unit Oil Cooler (307-07C Power Transfer Unit — 2 L EcoBoost (177 kW/240 L PS) — MI4, Removal).
   Refer to: Power Transfer Unit — Vehicles without: Power Transfer Unit Oil Cooler (307-07C Power Transfer Unit — 2 L EcoBoost (177 kW/240 L PS) — MI4, Installation).

FWD (Front-Wheel Drive) Vehicles

3. Remove the RH front wheel and tire.
   Refer to: Wheels and Tires (204-04A Wheels and Tires, Removal and Installation).

All vehicles

1. 1
   Remove the upper air cleaner outlet tube.
   Refer to: Air Cleaner Outlet Tube (303-12B Intake Air Distribution and Filtration - 2 L EcoBoost (177 kW/240 L HP) - MI4, Removal and Installation).
2. 2
   Disconnect the turbocharger wastegate valve electrical connector, then disconnect the harness clip from the stud. Release the charge air cooler upper inlet pipe clip. Loosen the charge air cooler upper inlet pipe clamp, then remove the charge air cooler upper inlet pipe.

   

3. 3
   Loosen the air cleaner lower outlet tube clamp, then remove the air cleaner lower outlet tube.

   

FWD (Front-Wheel Drive) Vehicles

7. Remove the catalytic converter.
   Refer to: Catalytic Converter (309-00B Exhaust System - 2 L EcoBoost (177 kW/240 L HP) - MI4, Removal and Installation).
   Refer to: Catalytic Converter (309-00B Exhaust System - 2 L EcoBoost (177 kW/240 L HP) - MI4, Removal and Installation).

All-Wheel Drive (AWD) Vehicles

1. 1
   Remove the battery tray.
   Refer to: Battery Tray — 1.5 L EcoBoost (132 kW/180 L hp) — I3 (Y1)/2 L EcoBoost (177 kW/240 L hp) — MI4 (Battery 414-01, Battery Mounting and Cables, Removal and Installation).
2. 2
   Remove and discard the catalytic converter nuts, then remove the catalytic converter.

   

3. 3
   Remove and discard the gasket.

   

All vehicles

1. 1
   Remove and discard the bolts, then remove the turbocharger oil supply tube.

   

2. 2
   Remove the bolts, then remove and discard the turbocharger oil return tube.

   

3. 3
   Remove the bolt, then remove the outer half of the turbocharger coolant return tube.

   

4. 4
   1. Remove and discard the turbocharger coolant tube O-ring.
      Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

   2. NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

      Using brake cleaner and a nylon brush, clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining clip is not bent, and check the squareness of the O-ring seal area. Install new components as necessary.

   

5. 5
   Remove the bolt, then remove the outer half of the turbocharger coolant supply tube.

   

6. 6
   1. Remove and discard the turbocharger coolant tube O-ring.

   2. NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

      Using brake cleaner and a nylon brush, clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining clip is not bent, and check the squareness of the O-ring seal area. Inspect the rubber gasket. Install new components as necessary.
      Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

   

7. 7
   Disconnect the turbocharger electrical connector.

   

8. 8
   Remove the turbocharger mounting nuts, disconnect the coolant tube bracket, then remove the turbocharger.

   

9. 9
   Remove and discard the turbocharger gasket.

   

10. 10
    Remove the turbocharger mounting studs, if necessary.

    

11. 11
    Remove and discard the turbocharger exhaust flange studs.

    

12. 12
    If necessary, remove the turbocharger coolant tube bolt, then remove the turbocharger coolant return tube.

    

13. 13
    1. Remove and discard the turbocharger coolant tube O-ring.

    2. NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

       Using brake cleaner and a nylon brush, clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining bracket is not bent, and check the squareness of the O-ring seal area. Inspect the rubber gasket. Install new components as necessary.
       Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

    3. Inspect the rubber gasket. Install new components as necessary.

    

14. 14
    If necessary, remove the turbocharger coolant supply tube.

    

15. 15
    1. Remove and discard the turbocharger coolant tube O-ring.

    2. NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

       Using brake cleaner and a nylon brush, clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage, make sure the retaining clip is not bent, and check the squareness of the O-ring seal area. Install new components as necessary.
       Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

    3. Using brake cleaner and a nylon brush, clean the turbocharger coolant tube gasket sealing surface. Install new components as necessary.
       Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

    

Installation

All vehicles

1. 1
   • Install a new turbocharger coolant tube O-ring.

   • Lubricate the new O-ring and the tube sealing surface with clean engine coolant.
     Refer to: Specifications (303-03B Engine Cooling - 2 L EcoBoost (177 kW/240 L HP) - MI4, Specifications).

   

2. 2

   NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

   • Carefully use a nylon brush to remove the old O-ring residue, and use brake cleaner to flush the O-ring residue from the turbocharger tube O-ring bore. Inspect the area for deep scratches and pitting. Install new components as necessary.
     Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

   1. If removed, install the turbocharger coolant supply tube to the turbocharger. The lower coolant supply tube enters the turbocharger first.

   

3. 3
   1. If removed, install a new turbocharger coolant tube O-ring. Lubricate the turbocharger coolant tube O-ring with clean engine coolant.
      Refer to: Specifications (303-03B Engine Cooling - 2 L EcoBoost (177 kW/240 L hp) - MI4, Specifications).

   2. Lubricate the turbocharger coolant tube rubber seal with clean engine coolant.
      Refer to: Specifications (303-03B Engine Cooling - 2 L EcoBoost (177 kW/240 L hp) - MI4, Specifications).

   

4. 4

   NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

   • Carefully use a nylon brush to remove the old O-ring residue, and use brake cleaner to flush the O-ring residue from the turbocharger tube O-ring bore. Inspect the area for deep scratches and pitting. Install new components as necessary.
     Material: Motorcraft® Brake Parts Cleaner / ESR-M1 (ESR-M1 metal brake parts cleaner)

   1. If removed, install the turbocharger coolant return tube to the turbocharger. The lower coolant supply tube must first enter the turbocharger.

   2. If removed, install and tighten the turbocharger coolant tube bolt.
      Torque: 97 lb-in (11 N·m)

   

5. 5
   Install and tighten the turbocharger exhaust flange studs.
   Torque: 30 lb-ft (40 N·m)

   

6. 6
   If removed, install and tighten the turbocharger mounting studs.
   Torque: 159 lb-in (18 N·m)

   

7. 7
   Install a new turbocharger gasket.

   

8. 8
   Install the turbocharger, connect the coolant tube bracket, then install and tighten the turbocharger mounting nuts.
   Torque: 39 lb-ft (53 N·m)

   

9. 9
   Connect the turbocharger electrical connector.

   

10. 10
    Install a new turbocharger coolant tube O-ring. Lubricate the turbocharger coolant tube O-ring and rubber seal with clean engine coolant.
    Refer to: Specifications (303-03B Engine Cooling - 2 L EcoBoost (177 kW/240 L hp) - MI4, Specifications).

    

11. 11

    • NOTICE: Do not use a metallic brush. Damage to the sealing area may cause leaks.

      Carefully use a nylon brush to remove the old O-ring residue. Use brake cleaner to flush the O-ring residue from the turbocharger tube to the engine O-ring bore. Inspect the area for deep scratches and nicks. If necessary, install new components.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C

    1. Install the turbocharger coolant supply tube outer half, then install and tighten the turbocharger coolant supply tube bolt.
       Torque: 35 lb-ft (48 N·m)

    

12. 12
    Install a new turbocharger coolant tube O-ring. Lubricate the new O-ring and tube sealing surface with clean engine coolant.
    Refer to: Specifications (303-03B Engine Cooling - 2 L EcoBoost (177 kW/240 L hp) - MI4, Specifications).

    

13. 13

    • NOTICE: Do not use a metallic brush. Damage to the sealing area may cause leaks.

      Carefully use a nylon brush to remove the old O-ring residue. Use brake cleaner to flush the O-ring residue from the turbocharger tube to the engine O-ring bore. Inspect the area for deep scratches and nicks. If necessary, install new components.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C

    1. Install the turbocharger coolant return tube outer half, then install and tighten the turbocharger coolant return tube bolt.
       Torque: 97 lb-in (11 N·m)

    

14. 14

    NOTICE: Make sure new turbocharger oil return tube O-ring seal 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 with clean engine oil.
    Refer to: Specifications (Engine 303-01B - 2 L EcoBoost (177 kW/240 L hp) - MI4, Specifications).

    

15. 15

    NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

    • Carefully use a nylon brush to remove old O-ring residue, then use brake cleaner to wash O-ring residue from the turbocharger tube O-ring bore. Inspect the area for deep scratches and pitting. If necessary, install new components.

    1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.
       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C
       Torque: 97 lb-in (11 N·m)

    

16. 16

    NOTICE: Do not reuse the turbocharger oil filter, a new turbocharger oil filter must be used.

    NOTICE: Make sure new turbocharger oil supply tube O-rings and gaskets are used.

    Install a new turbocharger oil supply tube. O-rings, gaskets and the oil filter, if not already installed. Lubricate the O-rings with clean engine oil.
    Refer to: Specifications (Engine 303-01B - 2 L EcoBoost (177 kW/240 L hp) - MI4, Specifications).

    

17. 17

    • NOTICE: Do not use a wire brush. Damage to the sealing area will cause a leak.

      Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to flush the O-ring residue from the turbocharger and engine O-ring bores. Inspect the area for deep scratches and nicks. If necessary, install new components.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C

    1. Install and fully seat the turbocharger oil supply tube, then install and tighten the bolts.
       Torque: 97 lb-in (11 N·m)

    

All-Wheel Drive (AWD) Vehicles

1. 1
   Clean and inspect the gasket surfaces.

   

2. 2
   Install a new gasket.

   

3. 3
   Install the catalytic converter, then at this stage hand-tighten the new nuts.

   

4. 4
   Tighten the catalytic converter nuts.
   Torque: 30 lb-ft (40 N·m)

   

5. 5
   Install the battery tray.
   Refer to: Battery Compartment - 1.5 L EcoBoost (132 kW/180 L PS) - I3 (Y1)/2 L EcoBoost (177 kW/240 L PS) - MI4 (Battery 414-01, Wiring and Cables, Removal and Installation).

FWD (Front-Wheel Drive) Vehicles

23. Install the catalytic converter.
    Refer to: Catalytic Converter (309-00B Exhaust System - 2 L EcoBoost (177 kW/240 L hp) - MI4, Removal and Installation).
    Refer to: Catalytic Converter (309-00B Exhaust System - 2 L EcoBoost (177 kW/240 L hp) - MI4, Removal and Installation).

All vehicles

1. 1
   Install the air cleaner lower outlet duct, then tighten the air cleaner lower outlet duct clamp.
   Torque: 44 lb-in (5 N·m)

   

2. 2
   Install the charge air cooler upper inlet pipe, then tighten the clamp. Insert the charge air cooler upper inlet pipe retaining clip. Attach the harness clip to the stud, then connect the turbocharger wastegate valve electrical connector.
   Torque: 44 lb-in (5 N·m)

   

3. 3
   Install the air cleaner upper outlet duct.
   Refer to: Air Cleaner Outlet Duct (303-12B Intake Air Distribution and Filtering - 2 L EcoBoost (177 kW/240 L hp) - MI4, Removal and Installation).

FWD (Front-Wheel Drive) Vehicles

27. Install the right front wheel and tire.
    Refer to: Wheels and Tires (204-04A Wheels and Tires, Removal and Installation).

All-Wheel Drive (AWD) Vehicles

28. Install the power transfer unit.
    Refer to: Power Transfer Unit - Vehicles With: Power Transfer Unit Oil Cooler (307-07C Power Transfer Unit - 2 L EcoBoost (177 kW/240 L PS), Installation).
    Refer to: Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil Cooler (307-07C Power Transfer Unit - 2 L EcoBoost (177 kW/240 L PS), Installation).

All vehicles

1. 1
   Check the engine oil level and add oil as necessary.
   Refer to: Specifications (303-01B Engine - 2 L EcoBoost (177 kW/240 L PS) - MI4, Specifications).
2. 2
   Fill the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling - 2 L EcoBoost (177 kW/240 L PS) - MI4, General Procedures).