Removal And Installation

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Position a suitable protective material in front of the Charge Air Cooler (CAC) or damage to the CAC may occur.

All vehicles

Position the vehicle on a hoist. For additional information, refer to JACKING AND LIFTING article.
Disconnect the battery ground cable(s). For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Remove the Air Cleaner (ACL) assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.

Vehicles with brake vacuum pump

Drain the cooling system. For additional information, refer to ENGINE COOLING article.
Loosen the heater inlet hose clamp and disconnect the heater inlet hose.

All vehicles

Disconnect the crankcase vent oil separator tube from the crankcase vent oil separator.
Loosen the ACL outlet tube clamp and detach the ACL outlet tube from the turbocharger.
Remove the 4 bolts, the crankcase vent oil separator and the air cleaner outlet pipe as an assembly.
- Remove and discard the crankcase vent oil separator press-in-place gasket.
- To install, tighten to 13 Nm (115 lb-in).
Disconnect the PCM electrical connector and retainer. Disconnect the inline electrical connector and position the engine wiring harness on the engine.
Remove the 3 push nuts and the glow plug module heat shield.
- Discard the 3 push nuts.
Disconnect the high-pressure fuel injection pump electrical connector and detach the retainer from the glow plug module bracket.
Disconnect the glow plug module and the EGRT sensor electrical connectors, detach the wiring retainer and position the wiring harnesses aside.
Remove the nut and position the ground strap aside.
- To install, tighten to 13 Nm (115 lb-in).
Remove the engine wiring harness bolt.
- To install, tighten to 13 Nm (115 lb-in).
Remove the heater supply tube nut.
- To install, tighten to 13 Nm (115 lb-in).
Remove the 3 bolts and the glow plug module bracket.
- To install, tighten to 13 Nm (115 lb-in).

Vehicle with automatic transmission

Remove the nut and position the transmission fluid indicator tube aside.
- To install, tighten to 8 Nm (71 lb-in).

All vehicles

NOTE: Do not disconnect the glow plug electrical connector before dislodging the seal from the valve cover or the wiring harness may be damaged.

Using an appropriate tool, dislodge the glow plug wiring harness seals from the valve cover.
Disconnect the glow plug electrical connectors by pulling on the glow plug wiring harness tee above the seal. Remove the glow plug wiring harness.
Remove the nut and position the crankcase ventilation drain tube aside.
Disconnect the wiring harness retainer from the valve cover stud.
Disconnect the wiring harness retainer from the generator bracket.
Disconnect the A/C pressure switch electrical connector. Position the harness aside.

Fig 1: Locating A/C Pressure Switch Electrical Connector

Courtesy of FORD MOTOR CO.

NOTE: Do not bend or flex the heater supply tube or damage to the tube may occur.

Remove the 4 stud bolts, 6 bolts and the valve cover. Remove and discard the valve cover gasket.
- To install, tighten to 9 Nm (80 lb-in).
To install, reverse the removal procedure.
- Install a new valve cover gasket.
- Alternate tightening the valve cover bolts to tighten evenly.
- Install a new crankcase vent oil separator press-in-place gasket.