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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2544 (Turbocharger Cooling System -- F250-F550 Super Duty) >> Removal And Installation >> Fuel Cooler >> Installation

Fuel Cooler: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the fuel cooler and install the 2 fuel cooler bracket bolts, the 2 stud bolts and the 2 nuts.
    • Tighten the 2 bolts, 2 stud bolts and the 2 nuts in 3 stages.
      • Stage 1: Tighten the nuts to 19 Nm (168 lb-in).
      • Stage 2: Tighten the stud bolts to 24 Nm (18 lb-ft).
      • Stage 3: Tighten the bolts to 9 Nm (80 lb-in).
    2. NOTE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear opened. Failure to install the correct banjo bolt may result in damage to the fuel system.
  2. Install new sealing washers for the fuel pump-to-fuel cooler fuel tube, position the fuel tube and install the banjo bolt.
    • Tighten to 25 Nm (18 lb-ft).
    3. NOTE: Use only banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear opened. Failure to install the correct banjo bolt may result in damage to the fuel system.
    NOTE: Make sure that the fuel tubes are not rubbing against the turbocharger actuator cooler or damage to the fuel tubes may occur.
  3. Install new sealing washers for the fuel cooler-to-fuel filter fuel tube, position the fuel tube and install the banjo bolt.
    • Tighten to 25 Nm (18 lb-ft).
  4. Connect the coolant pump-to-fuel cooler hose to the fuel cooler.
  5. Connect the fuel cooler-to-coolant expansion tank hose to the fuel cooler.
  6. Fill and bleed the fuel and turbocharger cooling system. For additional information, refer to FUEL AND TURBOCHARGER COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  7. Pressurize the low-pressure fuel system. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
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