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Removal and Installation

WARNING: This page is about a different car, the 2012 Ford Pickup, 2012 Ford F550 Super Duty, 2012 Ford F450 Super Duty, and 2012 Ford Cab & Chassis. 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 AND 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.
    Fig 1: Identifying Radiator Hose Spring Clip
    G07411254Courtesy of FORD MOTOR CO.
  11. 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.
  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.
    Fig 2: Identifying Radiator Hose Spring Clip
    G07411254Courtesy of FORD MOTOR CO.
  13. 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.
  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. Refer to illustration.
    Fig 3: Positioning CAC And Fuel Cooler Hoses Under CAC
    G07970939Courtesy of FORD MOTOR CO.
  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.
    Fig 4: Identifying Radiator Hose Spring Clip
    G07411254Courtesy of FORD MOTOR CO.
  19. 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.
  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. Refer to illustration.
    Fig 5: Locating Lower Cooling Fan Shroud
    G07970941Courtesy of FORD MOTOR CO.
  24. Remove the four radiator bracket bolts and the 2 radiator brackets.
    • To install, tighten to 35 Nm (26 lb-ft).
  25. Refer to illustration.
    Fig 6: Identifying Radiator Bracket Bolts
    G07970942Courtesy of FORD MOTOR CO.
  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.
  28. 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.
  29. 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 AND DIAGNOSTICS .
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