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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 engine 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. Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS .
  4. Remove the radiator grille. EXTERIOR TRIM & ORNAMENTATION .
  5. Remove both headlamp assemblies. EXTERIOR LIGHTING SYSTEM .
  6. Remove the LH air deflector-to-radiator grille bracket pushpin.
  7. Remove the 2 lower bolts, the 4 upper bolts and the radiator grille bracket.
    • To install, tighten the 2 lower bolts to 3 Nm (27 lb-in).
    • To install, tighten the 4 upper bolts to 40 Nm (30 lb-ft).
  8. Release the clamp and disconnect the primary radiator overflow hose from the primary radiator.
  9. Detach the primary radiator overflow hose retainer, detach the primary radiator overflow hose from 2 places on the air cleaner outlet pipe resonator and position the primary radiator overflow hose aside.
  10. Disconnect the EGR cooler-to-secondary degas bottle hose from the secondary degas bottle. Detach the hose from the retainer on the air cleaner outlet pipe and position the hose aside.
  11. Remove the air cleaner outlet pipe and the air cleaner. INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
  12. 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 secondary degas bottle-to-secondary coolant pump hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the secondary degas bottle-to-secondary coolant pump hose from the secondary coolant pump.

    • To install, push the spring clip in place and connect the secondary degas bottle-to-secondary coolant pump hose quick connect coupling, making sure the coupling is secure.
      Fig 1: Identifying Radiator Hose Spring Clip
      G07411254Courtesy of FORD MOTOR CO.
  13. Remove the nut and disconnect the A/C condenser inlet fitting from the jumper line.
    • Remove and discard the O-ring seal and the gasket.
    • To install, tighten to 15 Nm (133 lb-in).
  14. Compress the tabs and disconnect the transmission fluid cooler-to-secondary degas bottle hose from the secondary degas bottle.
  15. Detach the transmission fluid cooler-to-secondary degas bottle hose retainer from the cooling fan stator.
  16. Detach the secondary radiator-to-EGR cooler hose retainer from the upper cooling fan shroud.
  17. Disconnect the horn electrical connector.
  18. Detach the 2 horn wiring harness retainers from the upper cooling fan shroud and the 1 wiring harness retainer from the lower cooling fan shroud.
  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 secondary 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 secondary coolant pump-to-secondary radiator hose from the secondary radiator T-connector.

    • To install, push the spring clip in place and connect the secondary coolant pump-to-secondary radiator hose quick connect coupling, making sure the coupling is secure.
      Fig 2: Identifying Radiator Hose Spring Clip
      G07411254Courtesy of FORD MOTOR CO.
  20. Release the clamp and disconnect the secondary radiator-to-EGR cooler hose from the secondary radiator.
  21. 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 primary radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the lower primary radiator hose from the primary radiator.

    • To install, push the spring clip in place and connect the lower primary radiator hose quick connect coupling, making sure the coupling is secure.
    Fig 3: Identifying Radiator Hose Spring Clip
    G07411254Courtesy of FORD MOTOR CO.
  22. Release the clamp and disconnect the secondary radiator-to-transmission fluid cooler hose from the secondary radiator.
  23. Remove the nut and disconnect the A/C condenser outlet fitting.
    • Remove and discard the O-ring seal and the gasket.
    • To install, tighten to 15 Nm (133 lb-in).
  24. Release the clamp and disconnect the Charge Air Cooler (CAC) and fuel cooler-to-secondary degas bottle hose from the secondary degas bottle. Position the hose aside.
  25. Remove the bolt and position the power steering fluid reservoir aside.
    • To install, tighten to 7 Nm (62 lb-in).
  26. 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 primary radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the upper primary radiator hose from the primary radiator.

    • To install, push the spring clip in place and connect the upper primary radiator hose quick connect coupling, making sure the coupling is secure.
      Fig 4: Identifying Radiator Hose Spring Clip
      G07411254Courtesy of FORD MOTOR CO.
  27. Detach the fuel cooler-to-secondary degas bottle hose retainer from the upper fan shroud.
  28. Detach the power steering fluid cooler-to-power steering fluid reservoir hose pushpin from the lower cooling fan shroud.
  29. Detach the 2 Charge Air Cooler Temperature (CACT) sensor wiring harness pushpins from the upper cooling fan shroud and 1 CACT sensor wiring harness pushpin from the lower cooling fan shroud.
  30. Open the hood latch cable connector housing, disconnect the cable, detach the cable retainer and position the cable aside.
  31. Disconnect the hood switch electrical connector and pushpin retainer.
    Fig 5: Locating Hood Switch Electrical Connector And Pushpin Retainer
    G06780055Courtesy of FORD MOTOR CO.
  32. Remove the 3 LH air deflector pushpins.
  33. Remove the bolts, open the retainers and position the power steering fluid cooler aside.
    • To install, tighten to 35 Nm (26 lb-ft).
  34. Release the clamp and disconnect the secondary radiator-to-CAC and fuel cooler hose from the secondary radiator.
  35. Detach the secondary radiator-to-CAC and fuel cooler hose retainer from the primary radiator and position the secondary radiator-to-CAC and fuel cooler hose aside.
  36. Detach the 3 front lower air deflector pushpins from the front bumper.
  37. Detach the 5 wiring harness retainers from the lower cooling fan shroud.
  38. Detach the front impact severity sensor wiring harness retainer from the lower cooling fan shroud.
  39. Remove the 2 radiator bolster bolts and with the help of an assistant the cooling module.
    • To install, tighten to 40 Nm (30 lb-ft).
  40. To install, reverse the removal procedure.
    • Install new gaskets and O-ring seals on the A/C fittings.
  41. NOTE: Evaluate the cooling system condition before filling the cooling system. Failure to follow these instructions can result in damage to the engine.
    NOTE: If installing a new engine or a new short block, fill the cooling system with new engine coolant. In these circumstances, flushing the engine and cooling system is not necessary.

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

  42. NOTE: Evaluate the cooling system condition before filling the secondary cooling system. Failure to follow these instructions can result in damage to the engine.
    NOTE: If installing a new engine or a new short block, fill the cooling system with new engine coolant. In these circumstances, flushing the engine and cooling system is not necessary.

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

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