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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.
    CAUTION: Make sure the ignition switch is in the OFF position prior to working on the electronic engine controls.
  1. Turn the ignition switch to the OFF position.
    2. WARNING: Never remove the pressure radiator relief cap while the engine is hot. Failure to follow these instructions can result in damage to the cooling system or engine or result in personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When certain all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.
    CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and system filled with new coolant.
    CAUTION: Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types.
  2. Partially drain the cooling system.
  3. Remove the retainers and the air deflector.
    Fig 1: Identifying Pushpin Retainers And Upper Air Deflector
    G03887856Courtesy of FORD MOTOR CO.
  4. Remove the power steering reservoir bracket retainers.
    Fig 2: Locating Power Steering Reservoir Bracket Retainers
    G03887857Courtesy of FORD MOTOR CO.
  5. Remove the power steering fluid indicator and retainers. Remove the power steering reservoir bracket. Install the power steering indicator and position aside.
    Fig 3: Identifying Power Steering Reservoir-To-Mounting Bracket Bolts
    G03887858Courtesy of FORD MOTOR CO.
  6. Disconnect the coolant hoses from the air cleaner outlet pipe.
    Fig 4: Locating Coolant Hoses & Air Cleaner Outlet Pipe
    G03887859Courtesy of FORD MOTOR CO.
    7. NOTE: Air cleaner side shown, engine side similar.
    Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp
    G03887860Courtesy of FORD MOTOR CO.
  7. Loosen the clamps and remove the air cleaner outlet pipe.
    8. 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
    G03887198Courtesy of FORD MOTOR CO.
  8. Loosen the clamps and remove the charge air cooler (CAC) pipe.
  9. Disconnect the engine coolant temperature (ECT) electrical connector.
    Fig 7: Disconnecting Engine Coolant Temperature (ECT) Electrical Connector
    G03888395Courtesy of FORD MOTOR CO.
  10. Remove the ECT sensor.
    Fig 8: Removing ECT Sensor
    G03888396Courtesy of FORD MOTOR CO.
    11. NOTE: Apply clean engine oil to the O-ring seal before installation.
  11. To install, reverse the removal procedure.
    • Fill and bleed the engine cooling system. For additional information refer to ENGINE COOLING .
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