Removal and Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

Drain the engine cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Remove the air cleaner assembly. Refer to INTAKE AIR DISTRIBUTION & FILTERING .

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

NOTE: Engine side shown, charge air cooler (CAC) side similar.

Fig 1: Removing Charge Air Cooler Duct

Courtesy of FORD MOTOR CO.

Remove the charge air cooler duct.
Late build

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

Fig 2: Removing Charge Air Cooler Duct

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the charge air cooler duct.
All vehicles
Disconnect and position the upper radiator hose aside.

Fig 3: Positioning Upper Radiator Hose Aside
Courtesy of FORD MOTOR CO.
Disconnect the exhaust backpressure sensor electrical connector and retaining clip.

Fig 4: Disconnecting Exhaust Backpressure Sensor Electrical Connector And Retaining Clip
Courtesy of FORD MOTOR CO.
Disconnect the exhaust backpressure tube at the exhaust manifold.

Fig 5: Disconnecting Exhaust Backpressure Tube At Exhaust Manifold
Courtesy of FORD MOTOR CO.
Remove the retaining nuts and exhaust backpressure assembly.

Fig 6: Removing retaining nuts and exhaust backpressure assembly
Courtesy of FORD MOTOR CO.
Remove the stud bolts and thermostat assembly.
- Remove and discard the O-ring.
  
  Fig 7: Removing Stud Bolts And Thermostat Assembly
  Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
- Install a new O-ring on the thermostat assembly.