Removal and Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Drain the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Remove the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
Loosen the clamps and remove the charge air cooler duct.
- To install, tighten to 12 Nm (9 lb-ft).
  
  Fig 1: Removing Charge Air Cooler Duct
  Courtesy of FORD MOTOR CO.
Disconnect and position the upper radiator hose aside.
Disconnect the exhaust backpressure sensor electrical connector.
Disconnect the exhaust backpressure tube at the LH exhaust manifold.
- To install, tighten to 30 Nm (22 lb-ft).
Remove the 2 nuts and exhaust backpressure sensor and bracket as an assembly.
- To install, tighten to 31 Nm (23 lb-ft).
Remove the 2 stud bolts and thermostat assembly.
- Remove and discard the O-ring seal.
- To install, tighten to 27 Nm (17 lb-ft).
To install, reverse the removal procedure.
- Install a new O-ring seal on the thermostat assembly.