Removal And Installation

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
Remove the turbocharger inlet tube. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.

NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the Charge Air Cooler (CAC) pipe to prevent the pipe from blowing off.

Loosen the clamps and remove the CAC pipe.
- To install, tighten to 12 Nm (106 lb-in).

Fig 1: Identifying Charge Air Cooler (CAC) Pipe Clamps

Courtesy of FORD MOTOR CO.

Disconnect the oil level indicator and tube from the stator.

Fig 2: Oil Level Indicator & Tube

Courtesy of FORD MOTOR CO.

Disconnect the glow plug wire retainer, remove the nut and position the oil level indicator and tube aside.
- To install, tighten to 8 Nm (71 lb-in).

Fig 3: Oil Level Indicator Tube Nut

Courtesy of FORD MOTOR CO.

Disconnect the glow plug module electrical connectors.

Fig 4: Glow Plug Module Electrical Connectors

Courtesy of FORD MOTOR CO.

Disconnect the Exhaust Pressure (EP) sensor electrical connector and pushpin retainer.

Fig 5: Identifying Exhaust Pressure Sensor Electrical Connector and Retainer

Courtesy of FORD MOTOR CO.

Disconnect the EP tube at the exhaust manifold.
- To install, tighten to 30 Nm (22 lb-ft).

Fig 6: Exhaust Pressure Tube At Exhaust Manifold

Courtesy of FORD MOTOR CO.

Remove the 2 nuts and the glow plug module.
- To install, tighten to 8 Nm (71 lb-in).

Fig 7: Glow Plug Module Nuts

Courtesy of FORD MOTOR CO.

Remove the 3 nuts and the glow plug module mounting bracket.
- To install, tighten to 8 Nm (71 lb-in).

Fig 8: Glow Plug Module Mounting Bracket Nuts

Courtesy of FORD MOTOR CO.

NOTE: To prevent engine damage, do not use air-powered tools when installing the crankcase breather.

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

If servicing the crankcase breather, remove the 6 bolts and the crankcase breather.
- Discard the 4 crankcase breather gaskets.
- To install, tighten to 7 Nm (62 lb-in).

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

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

Remove the 11 retainers and the valve cover.
- Clean and inspect the valve cover gasket.
- To install, tighten to 9 Nm (80 lb-in).
To install, reverse the removal procedure.