Turbocharger

This procedure covers the removal and replacement of one or both turbochargers on the 3.5L EcoBoost V6 engine, including disconnection of oil feed/return lines, coolant lines, exhaust components, and associated sensors.

Warnings

Tools required

Parts

• Turbocharger assembly (specify left or right bank) × 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
• Exhaust manifold nuts (set of 6) × 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 surface and engage parking brake
2. Disconnect negative battery terminal and wait 2 minutes for system depowerment
3. Allow engine to cool completely (minimum 4 hours after last operation)
4. Raise and support vehicle securely on jack stands
5. Remove engine belly pan/splash shield for access to underside components
6. Drain engine coolant into appropriate container by opening radiator petcock and lower coolant hose
7. Remove air intake system from throttle body to turbo inlet (save all clamps and hardware)
8. Label and photograph all electrical connections, vacuum lines, and coolant hoses before disconnection

Procedure

1. 1

   Remove heat shields and protective covers
   Remove the turbocharger heat shields by removing the retaining bolts. There are typically upper and lower heat shields protecting each turbocharger. Note the position of any spacers or insulators for reinstallation.
   Torque spec

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

   Disconnect electrical connections and sensors
   Disconnect the electrical connector from the turbocharger wastegate actuator. Remove the oxygen sensor(s) from the turbocharger outlet using an oxygen sensor socket. Disconnect any temperature or pressure sensors mounted on or near the turbocharger assembly. Remove sensor mounting hardware as needed.
   ⚠Oxygen sensors are fragile when cold. If sensors are seized, apply penetrating oil and allow to soak, or warm engine slightly before removal.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)

   Electrical Connector Bolts8 Nm (6 lb-ft)
3. 3

   Disconnect turbocharger oil feed line
   Locate the oil feed line connection at the top of the turbocharger housing. Using appropriate wrench or crowfoot, carefully loosen and remove the banjo bolt or fitting. Have a rag ready to catch residual oil. Note the position of crush washers on both sides of the banjo fitting.
   ℹ️Do not reuse the copper crush washers. New washers must be installed during reassembly.
   Torque spec

   Oil Feed Line20 Nm (15 lb-ft)
4. 4

   Disconnect turbocharger oil return line
   From underneath the vehicle, locate the oil return line connection at the bottom of the turbocharger center housing. Remove the bolts securing the return line flange to the turbocharger. Allow any residual oil to drain into the drain pan. Remove and discard the gasket.
   Torque spec

   Oil Return Line10 Nm (7 lb-ft)
5. 5

   Disconnect coolant lines from turbocharger
   Locate the coolant inlet and outlet lines connected to the turbocharger center housing (used for bearing cooling). Using appropriate wrenches, disconnect both coolant line fittings. Be prepared for coolant spillage. Inspect O-rings and replace during installation.
   ⚠Even with coolant drained, residual coolant will remain in lines and turbo passages. Keep drain pan positioned appropriately.
   Torque spec

   Coolant Line Fittings15 Nm (11 lb-ft)
6. 6

   Remove turbocharger outlet/downpipe connection
   From underneath the vehicle, locate the connection between the turbocharger outlet and the downpipe/exhaust system. Remove the bolts or v-band clamp securing this connection. Support the downpipe to prevent strain on downstream exhaust components. Remove and discard the gasket.
   ⚠Exhaust hardware is often corroded. Use penetrating oil and allow to soak if bolts are difficult to remove. Have replacement hardware available if fasteners are damaged during removal.
   Torque spec

   Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
7. 7

   Remove turbocharger-to-exhaust manifold fasteners
   Locate the bolts or studs securing the turbocharger inlet flange to the exhaust manifold. Working from the hottest cylinder (closest to center of engine) to the coldest (outermost), remove the fasteners. The turbocharger may now be loose but still blocked by surrounding components.
   ℹ️Ford specifies working hot-to-cold pattern to minimize warping risk. This refers to cylinder firing order heat distribution on the manifold.
   Torque spec

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

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
8. 8

   Remove turbocharger assembly
   Carefully maneuver the turbocharger assembly away from the exhaust manifold and out of the engine bay. This may require tilting, rotating, or removing additional brackets or supports. On some installations, the turbocharger must be removed from below the vehicle. Take care not to damage surrounding components or wiring harnesses. Remove and discard the turbo-to-manifold gasket.
9. 9

   Clean all mating surfaces
   Using a plastic gasket scraper and brake cleaner, thoroughly clean the exhaust manifold mounting surface, downpipe flange, oil return flange area, and any other mating surfaces. Remove all old gasket material, carbon deposits, and corrosion. Inspect surfaces for warping, cracks, or damage. The manifold surface must be completely clean and flat for proper sealing.
   ⚠Do not use metal scrapers on aluminum surfaces as this can cause gouging and leak paths. Use only plastic scrapers and appropriate solvents.
10. 10

    Prepare and install new turbocharger
    Before installation, verify the new turbocharger spins freely by hand (slight resistance is normal from bearing oil film). Apply a small amount of clean engine oil to the turbo bearing through the oil feed port. Install new gasket on exhaust manifold flange. Apply anti-seize compound to turbo-to-manifold bolt threads. Position new turbocharger onto exhaust manifold, ensuring gasket alignment.
    ⚠️Never start the engine without first priming the turbocharger oil system. Running a dry turbocharger will cause immediate catastrophic bearing failure.
11. 11

    Install turbocharger-to-manifold fasteners
    Install the turbo-to-manifold bolts with anti-seize compound applied to threads. Thread all bolts by hand first to ensure proper alignment. Torque bolts to specification in a cross-pattern sequence to ensure even clamping force and proper gasket seating.
    Torque spec

    Turbo-to-Manifold Bolts35 Nm (26 lb-ft)
12. 12

    Connect turbocharger outlet to downpipe
    Install new gasket between turbocharger outlet and downpipe flange. Align the connection and install bolts or v-band clamp. Ensure proper alignment to prevent exhaust leaks and stress on components. Torque fasteners to specification.
    Torque spec

    Turbo-to-Downpipe Bolts45 Nm (33 lb-ft)
13. 13

    Reconnect coolant lines
    Install new O-rings or gaskets on coolant line fittings. Connect coolant inlet and outlet lines to turbocharger center housing. Ensure proper seating and thread engagement before tightening. Torque fittings to specification, being careful not to cross-thread aluminum housings.
    Torque spec

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

    Reconnect oil return line
    Install new gasket on oil return line flange. Position the return line to the turbocharger center housing and install mounting bolts. Ensure proper alignment to prevent oil leaks. Torque bolts to specification.
    Torque spec

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

    Reconnect oil feed line
    Install new copper crush washers on both sides of the oil feed line banjo fitting (one against turbo housing, one under banjo bolt head). Connect oil feed line to turbocharger and install banjo bolt. Torque to specification. Verify crush washers are properly positioned.
    ℹ️Proper crush washer installation is critical. The washers should compress slightly when torqued but not over-tightened which can crack the housing.
    Torque spec

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

    Reinstall sensors and electrical connections
    Install oxygen sensor(s) into turbocharger outlet. Apply anti-seize to sensor threads (avoid getting anti-seize on sensor element). Reinstall any temperature or pressure sensors with new sealing washers if applicable. Reconnect all electrical connectors to wastegate actuator and sensors. Torque sensor mounting hardware to specification.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
17. 17

    Reinstall heat shields and covers
    Reinstall upper and lower turbocharger heat shields with all insulators and spacers in their original positions. Install and torque heat shield bolts to specification. Ensure heat shields do not contact moving components or create rattle points.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)

Reassembly

1. Reinstall air intake system from turbocharger inlet to throttle body, ensuring all clamps are tight
2. Reinstall engine belly pan/splash shield
3. Lower vehicle from jack stands
4. Refill cooling system with Motorcraft Orange Coolant to proper level, bleed air from system per manufacturer procedure
5. Reconnect negative battery terminal
6. Before starting engine, disconnect ignition coils or fuel pump fuse and crank engine for 15-20 seconds to prime turbocharger oil system
7. Reinstall ignition coils or fuel pump fuse, then start engine and verify no leaks

Verification

• With engine running at idle, inspect all connection points (oil feed/return, coolant lines, exhaust flanges) for leaks
• Listen for abnormal turbocharger noises such as grinding, squealing, or excessive whistling
• Allow engine to reach operating temperature and verify coolant level remains stable (no air pockets)
• Check for exhaust leaks by observing exhaust gas escape at all connection points
• Perform a test drive and verify proper boost pressure, smooth acceleration, and no check engine lights
• After test drive, re-inspect all connections while engine is hot for any leaks that may appear under thermal expansion
• Check oil level and top off if necessary (some oil loss during turbo removal is normal)
• Monitor for the first 100 miles for any oil consumption issues, coolant loss, or performance problems

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