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Removal and Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
  1. Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  2. Drain the secondary cooling system. For additional information, refer to ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .
  3. Evacuate the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
  4. Remove the upper cooling fan shroud. For additional information, refer to COOLING FAN SHROUD - UPPER .
  5. Remove the grille. For additional information, refer to EXTERIOR TRIM AND ORNAMENTATION .
  6. Remove the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  7. Remove the secondary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  8. Remove the 2 Charge Air Cooler (CAC) bolts.
    • To install, tighten to 12 Nm (106 lb-in).
  9. Remove the top 2 secondary radiator bolts.
    • To install, tighten to 11 Nm (97 lb-in).
  10. Remove the condenser inlet jumper line fitting nut and disconnect the compressor-to-condenser discharge line from the jumper line.
    • Remove and discard the O-ring seal and the gasket.
    • To install, install a new O-ring seal and gasket.
    • To install, tighten to 15 Nm (133 lb-in).
  11. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.

    Pull the coolant pump-to-secondary radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the coolant pump-to-secondary radiator coolant pump-to-radiator T-connector from the T-connector.

    • To install, push the spring clip in place and connect the coolant pump-to-secondary radiator hose quick connect coupling, making sure the coupling is secure.
      Fig 1: Identifying Radiator Hose Spring Clip
      G07411254Courtesy of FORD MOTOR CO.
  12. Release the clamp and disconnect the secondary radiator-to-EGR cooler hose from the radiator.
  13. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.

    Pull the upper radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the upper radiator hose from the radiator.

    • To install, push the spring clip in place and connect the upper radiator hose quick connect coupling, making sure the coupling is secure.
    Fig 2: Identifying Radiator Hose Spring Clip
    G07411254Courtesy of FORD MOTOR CO.
  14. Detach the secondary radiator-to-Charge Air Cooler (CAC) and fuel cooler hose retainer from the radiator.
  15. Detach the power steering hose retainer from the lower cooling fan shroud.
  16. Squeeze the tabs, disconnect the secondary radiator-to-CAC quick connect coupling from the CAC and position the CAC and fuel cooler hoses under the CAC.
  17. G07970939
  18. Remove the 2 lower cooling fan shroud bolts.
    • To install, tighten to 7 Nm (62 lb-in).
  19. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.

    Pull the lower radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the lower radiator hose from the radiator.

    • To install, push the spring clip in place and connect the lower radiator hose quick connect coupling, making sure the coupling is secure.
      Fig 3: Identifying Radiator Hose Spring Clip
      G07411254Courtesy of FORD MOTOR CO.
  20. Remove the 3 lower air deflector pushpins from the front bumper.
  21. Remove the bottom 2 secondary cooling system radiator bolts.
    • To install, tighten to 11 Nm (97 lb-in).
  22. Secure the lower cooling fan shroud rearward to the cooling fan stator.
  23. G07970941
  24. Remove the four radiator bracket bolts and the 2 radiator brackets.
    • To install, tighten to 35 Nm (26 lb-ft).
  25. G07970942
  26. With the help of an assistant, remove the radiator.
  27. To install, reverse the removal procedure.
  28. NOTE: Evaluate the cooling system condition before filling the cooling system. Failure to follow these instructions can damage the engine.

    Evaluate the cooling system condition. For additional information, refer to COOLING SYSTEM CONDITION EVALUATION .

  29. NOTE: Evaluate the cooling system condition before filling the secondary cooling system. Failure to follow these instructions can damage the engine.

    Evaluate the secondary cooling system condition. For additional information, refer to COOLING SYSTEM CONDITION EVALUATION in ENGINE COOLING - 6.7L DIESEL POWERTRAIN SECONDARY COOLING .

  30. Evacuate, leak test and charge the refrigerant system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
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