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 engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .

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

NOTE: Charge air cooler (CAC) side shown, turbocharger side similar.

Fig 1: Loosening CAC Tube Clamps

Courtesy of FORD MOTOR CO.

Loosen the CAC tube clamps.
Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.

Fig 2: Identifying Ground Wire Bolt & Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolt and position the manifold absolute pressure (MAP) assembly aside.

Fig 3: Removing Bolt And Position Manifold Absolute Pressure (MAP) Assembly
Courtesy of FORD MOTOR CO.
Remove the bolts and position the wiring aside

Fig 4: Removing Bolts And Positioning Wiring Aside
Courtesy of FORD MOTOR CO.
Remove the bolts for the charge air cooler tube and the oil fill tube.

Fig 5: Locating CAC Tube And Oil Fill Tube Bolts
Courtesy of FORD MOTOR CO.
Disconnect and remove the oil fill tube at the valve cover.

Fig 6: Identifying Oil Fill Tube At Valve Cover
Courtesy of FORD MOTOR CO.
Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.

Fig 7: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket
Courtesy of FORD MOTOR CO.
Disconnect the engine oil temperature (EOT) sensor.

Fig 8: Locating Engine Oil Temperature Sensor
Courtesy of FORD MOTOR CO.
Remove the EOT sensor.

Fig 9: Removing EOT Sensor
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.