Turbocharger

This procedure covers removal and replacement of one or both turbochargers on the 3.5L EcoBoost V6 engine, including all oil, coolant, and exhaust connections.

Warnings

Tools required

Parts

• Turbocharger assembly (left or right as needed) × 1 — Use OEM Ford turbocharger
• Turbocharger oil feed line crush washers × 2 — Use OEM specification
• Turbocharger oil return gasket × 1 — Use OEM specification
• Exhaust manifold gaskets × 1 — Use OEM specification
• Turbo to downpipe gasket × 1 — Use OEM specification
• Coolant line O-rings or gaskets × 2 — Use OEM specification

Fluids

• Motorcraft Orange Coolant — 2 qt
• Motorcraft 0W-20 Full Synthetic — 1 qt

Preparation

1. Park vehicle on level ground and allow engine to cool completely (minimum 3 hours after operation)
2. Disconnect negative battery cable and secure away from terminal
3. Remove engine cover by pulling upward on retaining clips
4. Raise and support vehicle on jack stands at frame contact points
5. Remove right front wheel for improved access to lower components
6. Remove right front wheelwell liner (plastic push pins and screws)
7. Place drain pan beneath engine and drain approximately 2 quarts of coolant from radiator petcock
8. Relieve fuel system pressure if removing intake components for left turbo access
9. Apply penetrating lubricant to all visible exhaust fasteners

Procedure

1. 1

   Remove charge air cooler outlet pipe and intercooler connections
   Disconnect the charge air cooler outlet pipe from the turbocharger compressor outlet using a flat blade screwdriver to release spring clamps. Remove the pipe assembly by wiggling and pulling upward. Disconnect any electrical connectors on the boost pressure sensor if equipped.
2. 2

   Disconnect turbocharger coolant lines
   Locate the coolant feed and return lines connected to the turbocharger center housing. Use a flare nut wrench to carefully loosen the fittings. Have a drain pan ready as coolant will drain from these lines. Cap or plug the lines immediately to prevent contamination.
   ⚠Coolant may still be warm and under residual pressure. Loosen fittings slowly.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
3. 3

   Remove heat shields
   Remove the turbocharger heat shield bolts and carefully remove the heat shield. There may be multiple pieces including an upper and lower shield. Note the position and orientation of all shields for reinstallation.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
4. 4

   Disconnect oil feed line
   Locate the oil feed line connected to the top of the turbocharger center housing. Use a crow's foot wrench or line wrench to loosen the banjo bolt. Allow oil to drain into a pan. Remove and discard the old crush washers from both sides of the banjo fitting.
   ℹ️Oil will drain from this line. Position drain pan accordingly.
   Torque spec

   Oil Feed Line20 Nm (15 lb-ft)
5. 5

   Disconnect oil return line
   From underneath the vehicle, locate the oil return line connected to the bottom of the turbocharger. Remove the bolts securing the oil return flange to the turbocharger. The line may contain residual oil. Remove the old gasket and discard.
   Torque spec

   Oil Return Line10 Nm (7 lb-ft)
6. 6

   Disconnect wastegate actuator and sensors
   Disconnect the electrical connector from the wastegate control solenoid and any temperature or pressure sensors mounted on the turbocharger. Remove any vacuum lines connected to the wastegate actuator. Label connections if needed for reassembly reference.
7. 7

   Remove turbocharger to downpipe connection
   From underneath the vehicle, locate the V-band clamp or bolted connection between the turbocharger outlet and the downpipe. If V-band equipped, loosen the clamp bolt and separate. If bolted, remove all turbo-to-downpipe bolts. Support the downpipe to prevent it from dropping.
   ⚠Downpipe is heavy. Support it with a jack or stand to prevent damage to oxygen sensors or hangers.
   Torque spec

   Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
8. 8

   Remove exhaust manifold to turbocharger nuts
   Working from above and below as needed, remove all nuts securing the turbocharger to the exhaust manifold. There are typically 4-6 nuts. Work in a cold-to-hot pattern (outside to inside) to minimize stud stress. If nuts are seized, apply additional penetrating lubricant and allow to soak before attempting removal.
   ⚠Exhaust studs are prone to breakage. Use penetrating lubricant and work slowly. If a stud breaks, it must be extracted before reassembly.
   Torque spec

   Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
9. 9

   Remove turbocharger assembly
   With all connections removed, carefully maneuver the turbocharger out of the engine bay. It may be necessary to rotate and angle the turbo to clear other components. The right side turbo typically comes out from above through the engine bay. Remove and discard the old exhaust manifold gasket.
10. 10

    Clean and inspect mounting surfaces
    Use a wire brush and scraper to thoroughly clean all gasket surfaces on the exhaust manifold and downpipe connection. Inspect exhaust manifold studs for damage or stretching. Replace any damaged studs. Vacuum debris from the area to prevent contamination. Inspect the oil drain port on the engine block and clean if needed.
    ⚠Do not allow debris to fall into exhaust ports or oil drain passages.
11. 11

    Prepare new turbocharger
    Remove shipping plugs from the new turbocharger oil and coolant ports. Pour approximately 30ml of clean engine oil into the oil feed port and rotate the compressor wheel by hand several times to distribute oil through the center bearing. Install new oil return gasket on the turbo drain flange.
    ℹ️Pre-lubrication is critical to prevent turbocharger bearing damage during initial startup.
12. 12

    Install turbocharger to exhaust manifold
    Position the new exhaust manifold gasket on the manifold studs. Carefully position the new turbocharger onto the exhaust manifold studs, ensuring the gasket remains properly seated. Apply anti-seize compound to the threads of the turbo-to-manifold nuts. Install all nuts finger-tight, then torque in a hot-to-cold pattern (center outward) to specification.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)

    Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
13. 13

    Connect turbocharger to downpipe
    Install new gasket or position V-band clamp between turbocharger outlet and downpipe. Align the connection carefully to avoid gasket damage. Apply anti-seize to bolt threads if using bolted connection. Torque bolts to specification or tighten V-band clamp securely.
    Torque spec

    Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
14. 14

    Connect oil return line
    Position the oil return line to the turbocharger drain flange with new gasket installed. Install bolts and torque to specification. Verify the line is not kinked or stretched.
    Torque spec

    Oil Return Line10 Nm (7 lb-ft)
15. 15

    Connect oil feed line
    Install new crush washers on both sides of the oil feed line banjo fitting. Position the oil feed line to the turbocharger and install the banjo bolt. Torque to specification. Do not overtighten as this will damage the crush washers.
    ⚠Always use new crush washers. Overtorquing will crush the washers excessively and cause leaks.
    Torque spec

    Oil Feed Line20 Nm (15 lb-ft)
16. 16

    Reconnect coolant lines
    Install new O-rings or gaskets on coolant line fittings if applicable. Connect coolant feed and return lines to the turbocharger center housing. Torque fittings to specification using a flare nut wrench to avoid rounding.
    Torque spec

    Coolant Line Fittings15 Nm (11 lb-ft)
17. 17

    Reinstall heat shields and connect electrical
    Reinstall all heat shield sections in their original positions. Torque heat shield bolts to specification. Reconnect all electrical connectors to wastegate solenoid and sensors. Reconnect any vacuum lines to the wastegate actuator.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
18. 18

    Reinstall charge air system
    Reinstall the charge air cooler outlet pipe to the turbocharger compressor outlet. Ensure all spring clamps are fully seated. Reconnect boost pressure sensor if equipped. Verify all connections are secure.

Reassembly

1. Reinstall wheelwell liner with all plastic push pins and screws
2. Reinstall right front wheel and torque lug nuts to Ford specification (150 lb-ft)
3. Lower vehicle from jack stands
4. Refill cooling system with Motorcraft Orange Coolant to proper level
5. Reconnect negative battery cable
6. Reinstall engine cover

Verification

• With ignition ON but engine OFF, check for any fault codes using a scan tool
• Start engine and allow to idle. Monitor for oil leaks at feed and return connections
• Check for coolant leaks at turbocharger coolant line connections
• Check for exhaust leaks at manifold and downpipe connections (listen and look for smoke)
• Allow engine to reach operating temperature and verify boost pressure builds normally during light acceleration
• Perform a test drive and verify normal turbocharger operation with no unusual noises, smoke, or performance issues
• After test drive, recheck all connections for leaks with engine at operating temperature
• Check engine oil level and top off if necessary
• Verify no warning lights or fault codes are present after test drive

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