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.

Turn the ignition switch to the OFF position.
Remove the retainers and the air deflector.

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

Fig 2: Removing Power Steering Reservoir Bracket Retainers
Courtesy of FORD MOTOR CO.
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
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.
Loosen the clamps and remove the air cleaner outlet pipe.

Fig 5: Identifying Air Cleaner Outlet Pipe & Clamp
Courtesy of FORD MOTOR CO.

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 cooler (CAC) pipe.

NOTE: Picture taken from inside the vehicle for clarity.

Fig 7: Identifying Intake Air Temperature (IAT2) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Disconnect the intake air temperature 2 (IAT2) sensor electrical connector.
Remove the IAT2 sensor.

Fig 8: Removing IAT2 Sensor
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.