Oil Cooler: Assembly

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.

Using clean engine oil, lubricate the 4 O-rings for the oil cooler and install the O-rings on the oil cooler.
- Install the brown O-rings on the bottom slots on the oil cooler.
- Install the black O-rings on the top slots of the oil cooler.
Fig 1: Locating O-Rings
Courtesy of FORD MOTOR CO.
If equipped with a threaded insert, lubricate the new O-ring seal with clean engine oil and install on the threaded insert.

Fig 2: Locating O-Ring Seal
Courtesy of FORD MOTOR CO.

NOTE: Be sure the threaded insert is well seated as it is held in place when the oil cooler cover is installed and secured to the oil cooler with mounting hardware.

Fig 3: Locating Oil Cooler Cover

Courtesy of FORD MOTOR CO.

If equipped with a threaded insert, install the threaded insert into the oil cooler cover.
Using clean engine oil, lubricate the 2 large O-rings and 1 small O-ring and install the O-rings in the oil cooler cover.

Fig 4: Locating O-Rings
Courtesy of FORD MOTOR CO.
Install a new blue oil cooler cover gasket onto the oil cooler cover.

Fig 5: Locating Blue Oil Cooler Cover Gasket
Courtesy of FORD MOTOR CO.
Place the new oil cooler on a flat, clean surface with the oil cooler ports facing up.

Fig 6: Locating Oil Cooler Ports Facing Up
Courtesy of FORD MOTOR CO.
Assemble the oil cooler assembly.
- Position the oil cooler cover onto the oil cooler. Press down firmly on the 2 corners of the oil cooler cover, which are inline with the oil cooler ports, until the O-rings are fully seated into the oil cooler cover.
Fig 7: Locating Oil Cooler Cover Onto Oil Cooler
Courtesy of FORD MOTOR CO.

NOTE: Do not tighten the 2 bolts at this time.

Fig 8: Locating Oil Cooler-To-Oil Cooler Cover Bolts

Courtesy of FORD MOTOR CO.

Install the 2 oil cooler-to-oil cooler cover bolts.

NOTE: Do not tighten the 2 nuts at this time.

Fig 9: Locating Oil Cooler-To-Oil Cooler Cover Nuts

Courtesy of FORD MOTOR CO.

Install the 2 oil cooler-to-oil cooler cover nuts.
Tighten the 2 oil cooler-to-oil cooler cover bolts.
- Tighten to 22 N.m (16 lb-ft).
Fig 10: Locating Oil Cooler-To-Oil Cooler Cover Bolts
Courtesy of FORD MOTOR CO.
Tighten the 2 oil cooler-to-oil cooler cover nuts.
- Tighten to 22 N.m (16 lb-ft).
Fig 11: Locating Oil Cooler-To-Oil Cooler Cover Nuts
Courtesy of FORD MOTOR CO.
Install the EGR coolant supply port.

Fig 12: Locating EGR Coolant Supply Port
Courtesy of FORD MOTOR CO.
Using clean engine oil, lubricate the press-in-place gasket and install in the EGR coolant supply cover.

Fig 13: Locating Press-In-Place Gasket
Courtesy of FORD MOTOR CO.
Install the EGR coolant supply cover and 2 bolts.
- Tighten to 10 N.m (89 lb-in).
Fig 14: Locating EGR Coolant Supply Cover And Bolts
Courtesy of FORD MOTOR CO.
Install new press-in-place gaskets in the oil filter base.

Fig 15: Locating Press-In-Place Gaskets
Courtesy of FORD MOTOR CO.

NOTE: The old oil cooler cover bolts or new self-tapping bolts will be used.

Fig 16: Identifying Oil Filter Base And Bolts

Courtesy of FORD MOTOR CO.

Install the oil filter base and 8 bolts.
1. Tighten the 5 bolts to 22 N.m (16 lb-ft).
2. Tighten the 3 bolts to 10 N.m (89 lb-in).
Install the oil cooler. For additional information, refer to OIL COOLER . If the oil cooler is being installed as part of an engine reassembly, refer to ASSEMBLY .