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Radiator - 6.0L Diesel: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the help of an assistant, position the radiator and CAC into the vehicle.
  2. From the bottom of the vehicle, connect the A/C condenser to the CAC and position the entire assembly into place.
    3. NOTE: LH side shown, RH side similar.
  3. Install the 2 A/C condenser bolts.
    • Tighten to 9 Nm (80 lb-in).
    4. Fig 1: A/C Condenser Bolts
    GF0011934Courtesy of FORD MOTOR CO.
    NOTE: Cooling module removed from vehicle for clarity.
  4. Install the fan shroud and 2 bolts.
    5. Fig 2: Fan Shroud Bolts
    GF0011940Courtesy of FORD MOTOR CO.
    NOTE: LH side shown, RH side similar.
  5. Install the 4 bolts and the radiator mounting brackets.
    • Tighten to 20 Nm (177 lb-in).
    6. Fig 3: Locating Radiator Mounting Brackets Bolts
    GF0044589Courtesy of FORD MOTOR CO.
  6. Install the closeout and 2 push pin retainers.
    7. Fig 4: Locating Push Pin Retainers
    GF0044588Courtesy of FORD MOTOR CO.
  7. Install the lower shroud and connect the transmission cooler hoses onto the lower shroud.
    8. Fig 5: Locating Transmission Cooler Hoses
    GF0044587Courtesy of FORD MOTOR CO.
  8. Install the 2 lower shroud bolts.
    • Tighten to 6 Nm (53 lb-in).
  9. Connect the lower radiator hose.
  10. Connect the transmission cooler hoses.
    11. Fig 6: Locating Transmission Cooler Hoses
    GF0044586Courtesy of FORD MOTOR CO.
  11. Install the lower air deflector and 4 bolts.
    12. Fig 7: Locating Bolts & Lower Air Deflector
    GF0044585Courtesy of FORD MOTOR CO.
  12. Install and connect the upper radiator hose.
    13. Fig 8: Upper Radiator Hose
    GF0011929Courtesy of FORD MOTOR CO.
  13. Connect the radiator vent hose.
    14. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC hose to prevent the hose from blowing off.
  14. Install the CAC hose and tighten the 2 clamps.
    • Tighten to 12 Nm (106 lb-in).
    15. Fig 9: Identifying Charge Air Cooler (CAC) Pipe Clamps
    GF0011928Courtesy of FORD MOTOR CO.
  15. Install the CAC tube and tighten the 2 clamps.
    • Tighten to 12 Nm (106 lb-in).
    16. Fig 10: Locating Clamps & Charge Air Cooler (CAC) Tube
    GF0044583Courtesy of FORD MOTOR CO.
  16. Install the ACL cover and connect the 3 clips. Connect the MAF sensor electrical connector.
    17. Fig 11: Locating Mass Air Flow (MAF) Sensor Electrical Connector & Clips
    GF0044582Courtesy of FORD MOTOR CO.
    NOTE: ACL side shown, other side similar.
  17. Install the ACL outlet tube and tighten the 2 clamps.
    18. Fig 12: Identifying Air Cleaner Outlet Pipe & Clamp
    G03887860Courtesy of FORD MOTOR CO.
  18. Connect the coolant hoses onto the ACL outlet pipe.
    19. Fig 13: Locating Coolant Hoses & Air Cleaner Outlet Pipe
    G03887859Courtesy of FORD MOTOR CO.
  19. Remove the power steering fluid indicator. Position the power steering reservoir and install the power steering reservoir mounting bracket. Install the 3 bolts and the power steering fluid indicator.
    20. Fig 14: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts
    G03887858Courtesy of FORD MOTOR CO.
  20. Install the 4 bolts for the power steering reservoir bracket.
    21. Fig 15: Locating Power Steering Reservoir Bracket Retainers
    G03887857Courtesy of FORD MOTOR CO.
  21. Install the upper air deflector and 6 push pin retainers.
    22. Fig 16: Locating Push Pin Retainers
    GF0044581Courtesy of FORD MOTOR CO.
  22. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding .
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