Lincoln Navigator: Fuel Charging and Controls - Turbocharger - 3.5L EcoBoost (272kW/370PS) / Turbocharger RH. Removal and Installation

Materials

Removal

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

NOTICE: Special attention needs to be given to the sealing ports for the oil feed, the oil drain, and the coolant tubes, on turbocharged engines. The sealing ports must be totally clean and free from O-ring residue, have no damage to the sealing surface and the tubes to ensure that there are no leaks or repeat repairs.

1. Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03 Engine Cooling - 3.5L EcoBoost (272kW/370PS), General Procedures).
   

1. Remove the engine rear undershield.
   

1. Remove the right front fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Remove the charge air cooler intake pipe - right side.
   Refer to: Charge Air Cooler (CAC) Intake Pipe (303-12 Intake Air Distribution and Filtering - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

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

1. Remove and discard the turbocharger fitting and oil filter assembly.
   

1. Remove the starter motor.
   Refer to: Starter Motor (303-06 Starting System - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

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

1. Disconnect the turbocharger wastegate control actuator electrical connector.
   

1. Remove the catalytic converter RH.
   Refer to: Catalytic Converter RH (309-00 Exhaust System - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. NOTICE: If the 2 piece turbocharger cooling tubes are separated or the rubber gasket is leaking, then the rubber gasket must be replaced.

   Remove the turbocharger coolant supply tube bolt, then disconnect the turbocharger coolant supply tube from the engine
   

1. NOTICE: If the 2 piece turbocharger cooling tubes are separated or the rubber gasket is leaking, then the rubber gasket must be replaced.

   Remove the turbocharger coolant return tube bolt, then disconnect the turbocharger coolant return tube from the engine.
   

1. NOTE: Remove the coolant tubes with the turbocharger. If the 2 piece turbocharger cooling tubes are separated, then the rubber gasket must be replaced.

   Remove and discard the turbocharger retainers, then remove the turbocharger.
   

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

   2. NOTICE: Do not use a metal brush, damage to sealing area will result in leaks.

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

1. NOTICE: If the 2 piece turbocharger cooling tubes were separated or the rubber gasket is leaking, then the rubber gasket must be replaced.

   If needed, then remove and discard the rubber gasket.
   

1. NOTICE: Do not use a metal brush, damage to sealing area will result in leaks.

   If needed, inspect and clean the turbocharger cooling tube sealing surfaces, using brake cleaner and a nylon brush to clean. Install new components if necessary.
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C

1. If needed, remove the turbocharger coolant tubes from the turbocharger.
   Refer to: Turbocharger Coolant Return Tube RH (303-04B Fuel Charging and Controls - Turbocharger - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   Refer to: Turbocharger Coolant Supply Tube RH (303-04B Fuel Charging and Controls - Turbocharger - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Remove and discard the turbocharger gasket.
   

1. If needed, remove the studbolts.
   

Installation

1. Make sure that the mating faces are clean and free of foreign material.
   

1. If removed, apply high temperature nickel anti-seize lubricant to the studbolt threads, then install and tighten the studbolts.
   Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2
   Torque: 30 lb.ft (40 Nm)

1. Install the new turbocharger gasket by pressing the gasket into the turbocharger flange groove evenly until at least 50% of the gasket is within the groove.
   

1. If removed, install the turbocharger coolant supply tubes.
   Refer to: Turbocharger Coolant Return Tube RH (303-04B Fuel Charging and Controls - Turbocharger - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   Refer to: Turbocharger Coolant Supply Tube RH (303-04B Fuel Charging and Controls - Turbocharger - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. 1. If needed, then install the turbocharger cooling tube rubber gasket. After installing the new rubber gasket, lubricate with clean engine coolant.
      Refer to: Specifications (303-03 Engine Cooling - 3.5L EcoBoost (272kW/370PS), Specifications).
      

1. Install the new turbocharger coolant tube O-ring seals Lubricate the new O-ring seal with clean engine coolant.
   Refer to: Specifications (303-03 Engine Cooling - 3.5L EcoBoost (272kW/370PS), Specifications).
   

1. NOTE: Install the coolant tubes to the engine with the turbocharger.

   1. NOTICE: Do not use a metal brush damage to sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if necessary.
      
   2. Install the turbocharger, then install and tighten the new turbocharger retainers as indicated in the following 3 stages.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C
      Torque:
        Stage 1:  Tighten 1-3 in the sequence shown to :   18 lb.in (2 Nm)
        Stage 2:  Tighten 1-3 in the sequence shown to :   38 lb.ft (51 Nm)
        Stage 3:  Re-tighten 1 to :   38 lb.ft (51 Nm)

1. Install and tighten the turbocharger coolant return tube bolt.
   Torque:
     Stage 1:  Tighten to. :   89 lb.in (10 Nm)
     Stage 2:  Tighten an additional 30 degrees or tighten to 16 Nm, whichever comes first. :   30°

1. Install and tighten the turbocharger coolant supply tube bolt.
   Torque:
     Stage 1:  Tighten to :   89 lb.in (10 Nm)
     Stage 2:  Tighten an additional :   30°

1. Install the catalytic converter RH.
   Refer to: Catalytic Converter RH (309-00 Exhaust System - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Connect the turbocharger wastegate control actuator electrical connector.
   

1. Lubricate the new turbocharger oil return tube O-ring seals with clean engine oil.
   Refer to: Specifications (303-01 Engine - 3.5L V6 PowerBoost (CN)) .
   

1. 1. NOTICE: Do not use a metal brush, damage to the sealing area will result in leaks.

      Carefully use a nylon brush to remove the old O-ring residue, use brake cleaner to rinse the O-ring residue out of the turbocharger and engine O-ring bores. Inspect the area for deep scratches and gouges. Install new components if necessary.
      
   2. Fully seat the turbocharger oil return tube into the turbocharger and engine bore holes flush to 2.5 mm off of the mounting surface prior to tightening the bolts. Install the new 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:
        Stage 1:  Tighten to :   89 lb.in (10 Nm)
        Stage 2:  Tighten an additional :   30°

1. Install the starter motor.
   Refer to: Starter Motor (303-06 Starting System - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Lubricate the new turbocharger fitting and oil filter assembly O-ring seal with clean engine oil.
   Refer to: Specifications (303-01 Engine - 3.5L V6 PowerBoost (CN)) .
   

1. 1. NOTICE: Do not use any brushes, damage to sealing area will result in leaks and possible internal turbo bearing damage.

      Use brake cleaner on a lint free rag to remove the O-ring residue out of the turbocharger fitting to engine block O-ring bore. Inspect the area for deep scratches and gouges. Install new components if necessary.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C
   2. Install and tighten the new turbocharger fitting, oil filter assembly.
      Torque: 24 lb.ft (32 Nm)

1. Lubricate the new turbocharger oil supply tube O-ring seals with clean engine oil.
   Refer to: Specifications (303-01 Engine - 3.5L V6 PowerBoost (CN)) .
   

1. 1. NOTICE: Do not use any brushes, damage to sealing area will result in leaks and possible internal turbo bearing damage.

      Use brake cleaner on a lint free rag to remove the O-ring residue out of the turbocharger and the engine oil filter adapter O-ring bores. Inspect the area for deep scratches and gouges. Install new components if necessary.
      
   2. Install the oil supply tube and the bolts, by simultaneously fully seating the oil supply tube into the turbocharger bore hole and the engine oil filter adapter bore hole flush to 2.5 mm off the mounting surface prior to tightening the bolts, then tighten the bolts in the following 2 stages.
      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C
      Torque:
        Stage 1:  Tighten to :   89 lb.in (10 Nm)
        Stage 2:  Tighten an additional :   30°

1. Install the charge air cooler intake pipe - right side.
   Refer to: Charge Air Cooler (CAC) Intake Pipe (303-12 Intake Air Distribution and Filtering - 3.5L EcoBoost (272kW/370PS), Removal and Installation).
   

1. Install the right fender splash shield.
   Refer to: Fender Splash Shield (501-02 Front End Body Panels, Removal and Installation).
   

1. Install the engine rear undershield.
   

1. Fill the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03 Engine Cooling - 3.5L EcoBoost (272kW/370PS), General Procedures).
   

1. Road test the vehicle.