Removal and Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Make sure the ignition switch is in the OFF position prior to working on the electronic engine controls.

Turn the ignition switch to the OFF position.
Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .

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

NOTE: Charge air cooler (CAC) side shown, turbocharger side similar.

Fig 1: Loosening CAC Tube Clamps

Courtesy of FORD MOTOR CO.

Loosen the CAC tube clamps.
Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.

Fig 2: Disconnecting Electrical Connector Push Pin
Courtesy of FORD MOTOR CO.
Remove the conduit and position the wiring aside.
- Disconnect the locking tab.
- Remove the bolts.
- Disconnect the push pin and remove the wiring harness.
Fig 3: Removing Wiring Harness
Courtesy of FORD MOTOR CO.
Remove the bolts for the charge air cooler tube and the oil fill tube.

Fig 4: Removing Bolts For Charge Air Cooler Tube And Oil Fill Tube
Courtesy of FORD MOTOR CO.
Disconnect and remove the oil fill tube at the valve cover.

Fig 5: Removing Oil Fill Tube At Valve Cover
Courtesy of FORD MOTOR CO.
Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.

Fig 6: Removing Retaining Nuts
Courtesy of FORD MOTOR CO.
Disconnect the engine oil temperature (EOT) sensor.

Fig 7: Disconnecting Engine Oil Temperature (EOT) Sensor
Courtesy of FORD MOTOR CO.
Remove the EOT sensor.

Fig 8: Removing EOT Sensor
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.