Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the retainers and the air deflector.

Fig 1: Identifying Pushpin Retainers And Upper Air Deflector
Courtesy of FORD MOTOR CO.
Remove the power steering reservoir bracket retainers.

Fig 2: Locating Power Steering Reservoir Bracket Retainers
Courtesy of FORD MOTOR CO.
Remove the power steering fluid indicator and retainers. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position the power steering reservoir aside.

Fig 3: Locating Power Steering Fluid Indicator And Retainers
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the air cleaner outlet pipe.

Fig 4: Locating Coolant Hoses At Air Cleaner Outlet Tube
Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, engine side similar.

Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the air cleaner outlet pipe.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler pipe to prevent the pipe from blowing off.

Fig 6: Charge Air Cooler Pipe Clamp With Torque Specifications

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the charge air cooler (CAC) pipe.
Remove the secondary fuel filter and remove all fuel from the filter housing.

Fig 7: Removing Secondary Fuel Filter
Courtesy of FORD MOTOR CO.
Disconnect the fuel return tube from the regulator cover.

Fig 8: Disconnecting Fuel Return Tube From Regulator Cover
Courtesy of FORD MOTOR CO.

WARNING: Clean all fuel residue from the engine compartment. Failure to follow these instructions may result in personal injury.

Fig 9: Removing Fuel Pressure Regulator Cover

Courtesy of FORD MOTOR CO.

Remove the screws and the fuel pressure regulator cover.
Remove and discard the fuel pressure regulator cover O-ring seal.

Fig 10: Discarding Fuel Pressure Regulator Cover O-Ring Seal
Courtesy of FORD MOTOR CO.
Remove the spring and poppet valve.
- Inspect the fixed orifice for foreign material.
  
  Fig 11: Removing Spring And Poppet Valve
  Courtesy of FORD MOTOR CO.
Clean the fuel pressure regulator bore in the fuel filter housing.
To install, reverse the removal procedure.