Turbocharger

Complete turbocharger replacement procedure for the 3.5L EcoBoost V6 engine, including removal of exhaust components, oil and coolant lines, and turbocharger assembly installation.

Warnings

Tools required

Parts

• Turbocharger assembly (left or right bank as needed) × 1 — Use OEM specification
• Turbocharger-to-manifold gasket × 1 — Use OEM specification
• Turbocharger-to-downpipe gasket × 1 — Use OEM specification
• Oil feed line crush washers × 2 — Use OEM specification
• Oil return line gasket × 1 — Use OEM specification
• Coolant line O-rings × 4 — Use OEM specification
• Exhaust manifold nuts (if corroded) × 6 — M8x1.25
• Heat shield bolts (if damaged) × 4 — Use OEM specification
• Engine coolant × 1 — Motorcraft Orange

Fluids

• Motorcraft Orange Coolant — 2 qt
• Motorcraft 5W-20 Synthetic Blend — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely for minimum 3 hours
3. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
4. Raise and support vehicle securely on jack stands at all four corners
5. Remove engine cover by pulling upward on snap clips
6. Drain cooling system by opening radiator petcock and removing upper radiator hose. Collect coolant in drain pan
7. Remove air intake tubes and air filter housing to access turbocharger area
8. For right side turbo: remove battery, battery tray, and washer fluid reservoir
9. Spray all exhaust fasteners with penetrating oil and allow to soak 30 minutes minimum

Procedure

1. 1

   Remove heat shields and charge air cooler tubes
   Remove upper heat shields covering the turbocharger using T30 Torx bit. Remove the charge air cooler (intercooler) tube connecting to turbo outlet by loosening hose clamps. Remove lower engine splash shields from underneath vehicle to access turbo from below.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
2. 2

   Disconnect exhaust downpipe from turbocharger
   Working from underneath vehicle, locate the three bolts connecting exhaust downpipe to turbo outlet. Support downpipe weight with jack stand or wire. Remove three bolts and separate downpipe, allowing it to hang supported. Remove and discard old gasket.
   ⚠Downpipe is heavy and awkward. Ensure it is properly supported to prevent damage to oxygen sensors or exhaust hangers.
   Torque spec

   Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
3. 3

   Remove oxygen sensors
   Disconnect electrical connectors from upstream and downstream oxygen sensors on the affected bank. Use oxygen sensor socket to remove both sensors from exhaust manifold and downpipe. Set sensors aside in safe location where threads will not be damaged.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
4. 4

   Disconnect coolant lines from turbocharger
   Locate coolant feed and return lines connecting to turbocharger housing. Place drain pan underneath. Use 13mm line wrench to loosen fittings at turbocharger end. Coolant will drain - capture in pan. Cap or plug coolant lines and turbo ports immediately to prevent contamination.
   ⚠Coolant lines are under slight residual pressure even when cold. Have rags ready to catch spillage.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
5. 5

   Disconnect oil feed line from turbocharger
   Locate oil feed line (high-pressure line from engine block to top of turbocharger). Use 18mm wrench to hold fitting on turbo while using 15mm wrench to loosen banjo bolt. Remove bolt and feed line. Note position of crush washers - discard both washers. Immediately plug turbo oil inlet port with clean lint-free rag to prevent contamination.
   ⚠️Absolutely no debris can enter turbo oil passages. Foreign material will cause immediate turbo failure. Keep all openings covered.
   Torque spec

   Oil Feed Line20 Nm (15 lb-ft)
6. 6

   Disconnect oil return line from turbocharger
   Working from underneath vehicle, locate oil return drain line from bottom of turbocharger to engine block. Remove bolts securing return line flange to turbocharger. Drain residual oil into drain pan. Remove and discard gasket. Cover turbo drain port with clean rag.
   Torque spec

   Oil Return Line10 Nm (7 lb-ft)
7. 7

   Remove turbocharger from exhaust manifold
   Working from above and below, locate the four bolts securing turbocharger to exhaust manifold. Apply anti-seize to threads if accessible. Support turbocharger weight with one hand or have assistant ready. Remove all four mounting bolts in crisscross pattern. Carefully wiggle turbocharger free from manifold studs and remove from engine bay. Remove and discard old gasket from manifold surface.
   ⚠Turbocharger weighs approximately 25 pounds and is awkward to handle in tight engine bay. Have clear removal path planned before unbolting.
   Torque spec

   Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
8. 8

   Clean all mating surfaces
   Thoroughly clean exhaust manifold face where turbo mounts using wire brush and gasket scraper. Remove all old gasket material and carbon buildup. Clean turbo mounting bolt threads with wire brush. Clean downpipe flange surface. Use shop vacuum to remove all debris - do not allow particles to enter exhaust ports or turbo oil passages. Inspect manifold face for cracks or warpage.
   ℹ️If exhaust manifold shows cracks around ports or mounting surfaces, it must be replaced before installing new turbocharger or premature failure will occur.
9. 9

   Prepare new turbocharger for installation
   Unbox new turbocharger and verify it matches old unit. Remove protective caps from oil and coolant ports. Pour approximately 1/2 quart fresh engine oil into turbo oil inlet port and rotate compressor wheel by hand 10-15 revolutions to pre-lubricate internal bearings. Drain excess oil from drain port. Install new turbo-to-manifold gasket onto manifold studs with raised bead facing turbo.
   ⚠️Never start engine with dry turbocharger bearings. Pre-lubrication is absolutely critical to prevent immediate bearing failure.
10. 10

    Install turbocharger to exhaust manifold
    Carefully guide new turbocharger into position, aligning mounting holes with exhaust manifold studs. Ensure gasket remains properly positioned. Install all four mounting bolts with anti-seize compound applied to threads. Hand-tighten all bolts first, then torque in crisscross pattern to specification.
    Torque spec

    Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
11. 11

    Reconnect oil return line
    Install new oil return line gasket onto turbo drain port. Position oil return line and hand-start mounting bolts. Torque bolts to specification. Verify line has proper clearance and is not kinked or stressed.
    Torque spec

    Oil Return Line10 Nm (7 lb-ft)
12. 12

    Reconnect oil feed line with new crush washers
    Install one new copper crush washer on each side of oil feed line banjo fitting. Position oil feed line to turbo inlet port. Install banjo bolt with washers and hand-tighten. Torque to specification using two wrenches - one to hold fitting steady, one to torque bolt. Verify washers are properly compressed.
    Torque spec

    Oil Feed Line20 Nm (15 lb-ft)
13. 13

    Reconnect coolant lines
    Install new O-rings onto coolant line fittings, lubricating lightly with clean coolant. Connect coolant feed and return lines to turbocharger ports. Hand-tighten fittings, then torque to specification using line wrenches. Ensure lines are not kinked and have adequate clearance from hot exhaust components.
    Torque spec

    Coolant Line Fittings15 Nm (11 lb-ft)
14. 14

    Reconnect exhaust downpipe
    Install new turbo-to-downpipe gasket onto turbo outlet flange. Raise downpipe into position and align with turbo outlet. Install three mounting bolts with anti-seize on threads. Torque in star pattern to specification. Verify downpipe hangs properly and is not stressed.
    Torque spec

    Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
15. 15

    Reinstall oxygen sensors and accessories
    Apply anti-seize to oxygen sensor threads (avoid getting any on sensor tip). Install upstream and downstream oxygen sensors and torque to specification. Reconnect electrical connectors ensuring they click fully into place. Reinstall heat shields and torque mounting bolts. Reinstall charge air cooler tubes with new clamps. Reinstall air intake system, engine covers, battery components if removed, and splash shields.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Refill cooling system with Motorcraft Orange coolant to proper level in overflow reservoir
2. Double-check all fasteners are torqued to specification and all electrical connectors are secured
3. Reconnect negative battery cable
4. Before first start: disconnect ignition coils and crank engine for 10-15 seconds to build oil pressure and circulate oil through new turbo without combustion
5. Reconnect ignition coils and start engine

Verification

• Start engine and verify no coolant, oil, or exhaust leaks around turbocharger connections. Check oil feed and return lines carefully
• Allow engine to idle for 5 minutes while monitoring for leaks and unusual noises
• Rev engine slowly to 2500 RPM several times and listen for turbo whistle or abnormal sounds
• Check coolant level after engine reaches operating temperature and top off as needed
• Test drive vehicle and verify normal boost pressure and performance. Monitor for smoke from exhaust or oil consumption
• After 100 miles, recheck all turbocharger fasteners for tightness and inspect for any fluid leaks
• Clear any diagnostic trouble codes and verify no boost-related fault codes return

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