Removal and Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Remove the push pin retainers and upper air deflector.

Fig 1: Identifying Pushpin Retainers And Upper Air Deflector
Courtesy of FORD MOTOR CO.
Remove the bolts for the power steering reservoir bracket.

Fig 2: Locating Power Steering Reservoir Bracket Retainers
Courtesy of FORD MOTOR CO.
Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.

Fig 3: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
Disconnect the coolant hoses from the air cleaner outlet tube.

Fig 4: Locating Coolant Hoses & Air Cleaner Outlet Pipe
Courtesy of FORD MOTOR CO.

NOTE: Air cleaner side shown, other side similar.

Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the air cleaner outlet tube.

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

Fig 6: Charge Air Cooler Pipe Clamp With Torque Specifications

Courtesy of FORD MOTOR CO.

Loosen the clamps and remove the charge air pipe.
Disconnect and position the upper radiator hose aside.

Fig 7: Disconnecting Upper Radiator Hose
Courtesy of FORD MOTOR CO.
Remove the retaining nut and position the fuel line retainer aside.

Fig 8: Identifying Fuel Line Retaining Bracket Nut
Courtesy of FORD MOTOR CO.
Remove the stud bolts and thermostat assembly.
- Remove and discard the O-ring seal.
  
  Fig 9: Removing Thermostat Assembly Stud Bolts
  Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
- Install a new O-ring seal on the thermostat assembly.