Removal and Installation
WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Remove the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
- Add Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent meeting Ford specification WSS-M97B51-A1. Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.
- Do not add orange-colored Motorcraft Specialty Orange Engine Coolant VC-2 or equivalent meeting WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.
- Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol anti-freeze. These can cause engine damage from overheating or freezing.
- Relieve the cooling system pressure and disconnect and cap the engine vent hose and the radiator vent hose.
- Remove the 2 bolts and position the degas bottle aside.
- To install, tighten to 10 Nm (89 lb-in).
- Release the 2 exhaust pressure (EP) sensor harness pin-type retainers.
- Disconnect the EP sensor electrical connector and position the harness aside.
- Disconnect the fitting at the exhaust manifold and remove the nut and the EP sensor tube.
- To install, tighten the EP sensor tube support bracket nut to 13 Nm (10 lb-ft).
- To install, tighten the EP sensor tube fitting at the exhaust manifold to 30 Nm (22 lb-ft).
- Remove the turbocharger inlet pipe mounting nuts and disconnect the vent tube.
- To install, tighten to 13 Nm (10 lb-ft).
- Loosen the clamp and remove the turbocharger inlet pipe.
- Remove the fuel injector control module mounting bolts and position the module for access to the electrical connectors.
- To install, tighten to 13 Nm (10 lb-ft).
- Disconnect the fuel injector control module electrical connectors and remove the fuel injector control module.
- Remove the nuts and the fuel injector control module mounting bracket.
- To install, tighten to 8 Nm (71 lb-in).
- Disconnect the wiring harness retainer and remove the nut and position the oil level indicator and tube aside.
- Remove the 5 bolts, the 6 stud bolts and the valve cover. Clean and inspect the valve cover gasket, and install a new gasket if necessary.
- To install, tighten to 9 Nm (80 lb-in).
- To install, reverse the removal procedure.
WARNING:
Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.
CAUTION:
The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and the system filled with new coolant.
CAUTION:
Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.
CAUTION:
Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water.
To maintain the integrity of the coolant and the cooling system:
When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water.
To maintain the integrity of the coolant and the cooling system:
CAUTION:
To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE:
Mark the position of the valve cover bolts for valve cover bolt installation.
CAUTION:
With the engine cold, fill vehicles without a yellow fill level decal on the degas bottle only to the MIN line. The correct fill level on these vehicles is between the MIN line and 15 mm (0.59 in) below the MIN line. Fill vehicles with a yellow fill level decal to within the yellow cold fill range shown on the decal. These fill levels will allow for coolant expansion. Overfilling the degas bottle may result in damage to the pressure cap, which can cause the engine to overheat.