Turbocharger. Removal and Installation

Materials

Removal

NOTICE: Whenever turbocharger intake system components are removed, always cover open ports to protect against debris. It is important to prevent foreign material from entering the system. The turbocharger compressor wheel blades are susceptible to damage from even small particles. All components must be inspected and cleaned, if necessary, before installation or reassembly.

1. 1
   Remove the air cleaner outlet tube.
   Refer to: Air Cleaner Outlet Tube (303-12B Intake Air Distribution and Filtration – 1.6 L EcoBoost (132 kW/180 L hp) – Sigma, Removal and Installation).
2. 2
   Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03B Engine Cooling – 1.6 L EcoBoost (132 kW/180 L hp) – Sigma, General Procedures).
3. 3
   Remove the coolant recovery reservoir.
   Refer to: Coolant Recovery Reservoir (303-03B Engine Cooling - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, Removal and Installation).
4. 4
   Remove the engine appearance cover.

   

5. 5
   1. Disconnect the crankcase vent tube quick-release coupling.
      Refer to: Quick-Release Coupling (310-00B Fuel System - General Information). Information - 1.6 L EcoBoost (132 kW/180 L PS) - Sigma, General Procedures).

   2. Remove the TC intake air duct lock nut, ball stud, and loosen the TC intake tube clamp, then remove the TC intake tube.
      Torque: 44 lb-in (5 N·m)

   

6. 6
   Raise and support the vehicle on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
7. 7
   Loosen the clamp and move the TC outlet pipe aside to clear the work area.
   Torque: 44 lb-in (5 N·m)

   

8. 8
   • Remove and discard the front axle shaft bearing bracket lower nut.

   • Remove and discard the front axle shaft bearing bracket upper nut.

   • Remove and discard the front axle shaft bearing bracket.
     Torque:
     Tighten the lower nut: 44 lb-in (5 N·m)
     Tighten the upper nut: 18 lb-ft (25 N·m)
     Tighten the lower nut: 18 lb-ft (25 N·m)

   

9. 9
   Remove the front axle shaft bearing bracket bolts, then move the axle shaft bearing bracket aside.
   Torque: 35 lb-ft (48 N·m)

   

10. 10
    Remove the catalytic converter.
    Refer to: Catalytic Converter (309-00B Exhaust System – 1.6 L EcoBoost (132 kW/180 L hp) – Sigma, Removal and Installation).
11. 11
    1. Remove the TC coolant tube bracket bolts.
       Torque: 17 lb-ft (23 N·m)

    2. Disconnect the TC coolant tube bolts from the TC.
       Torque: 21 lb-ft (28 N·m)

    3. Release the retainers, then disconnect the TC coolant tubes.

    4. Remove and discard the TC coolant tubes.

    5. Remove the TC heat shield bolts, then remove the TC heat shield.
       Torque: 159 lb.in (18 N·m)

    

12. 12
    Remove and discard the TC mounting nut.
    Torque: 18 lb.ft (25 N·m)

    

13. 13
    Remove the TC oil supply tube bolt and set the TC oil supply tube aside.
    Torque: 89 lb.in (10 N·m)

    

14. 14
    Remove the TC oil drain tube bolts, then remove the TC oil drain tube.
    Torque: 89 lb.in (10 N·m)

    

15. 15
    
    

    • Remove and discard the TC oil drain tube gasket. Inspect and, if necessary, replace the TC oil return tube O-ring.

    • To install, lubricate the TC oil return tube O-ring with clean engine oil.
      Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

16. 16
    Disconnect the TC electrical connectors.

    

17. 17
    • Remove and discard the TC mounting nuts and remove the TC.
      Torque:
      Stage 1: 18 lb.ft (25 N·m)
      Stage 2: 18 lb.ft (25 N·m)

    

18. 18
    1. Remove and discard the thermocouple mounting stud and gasket.
       Torque: 177 lb.in (20 N·m)

    2. Install a new TC oil supply tube assembly, then install and tighten the TC oil supply tube bolt.
       Torque: 19 lb.ft (26 N·m)

    3. Lubricate the O-ring of the new TC oil supply tube with clean engine oil.
       Material: Engine Oil — SAE 5W-20 — Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

19. 19
    Remove and discard the TC mounting studs.
    Torque: 177 lb.in (20 N·m)

    

Installation

1. NOTICE: Make sure that the mating surfaces are clean and free of foreign material.

   To install, reverse the removal procedure.