Removal and Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

Remove the RH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
Loosen the clamp at the charge-air-cooler (CAC).
- To install, tighten to 12 Nm (9 lb-ft).
  
  Fig 1: Identifying Charge-Air-Cooler Clamp
  Courtesy of FORD MOTOR CO.

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

Loosen the clamp at the turbocharger and remove the CAC duct.
- To install, tighten to 12 Nm (9 lb-ft).
  
  Fig 2: Locating CAC Duct
  Courtesy of FORD MOTOR CO.

NOTE: Only one wiring retainer shown.

Fig 3: Locating Wiring Retainers

Courtesy of FORD MOTOR CO.

Disconnect the wiring retainers from the studs.
Disconnect the pushpin retainer, the injection control pressure (ICP) and the glow plug module electrical connectors.

Fig 4: Locating Injection Control Pressure (ICP) Electrical Connector And Glow Plug Connectors
Courtesy of FORD MOTOR CO.
Disconnect the wiring harness retainers from the valve cover studs.

Fig 5: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Remove the 4 nuts and the glow plug module mounting bracket.
- To install, tighten to 9 Nm (80 lb-in).
  
  Fig 6: Locating Glow Plug Module Mounting Bracket Nuts
  Courtesy of FORD MOTOR CO.
Remove the ICP sensor.
- To install, tighten to 12 Nm (9 lb-ft).

Vehicle with automatic transmission

NOTE: Use a 6-point socket squarely seated on the retaining nut for removal.

Remove the retaining nut and position the transmission fluid indicator and tube assembly aside.
- Discard the retaining nut.
  
  Fig 7: Identifying Transmission Fluid Indicator Retaining Nut
  Courtesy of FORD MOTOR CO.

All vehicles

CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.

NOTE: The lower rear valve cover bolts are accessed from the wheel opening.

NOTE: Mark the position of the valve cover bolts for valve cover bolt installation.

Remove the 11 bolts and the valve cover. Clean and inspect the valve cover gasket and install a new gasket, if necessary.
- To install, tighten to 9 Nm (80 lb-in).
Remove the high pressure oil rail-to-valve cover gasket.

Fig 8: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
- Install a new retaining nut on the transmission indicator tube.