Cooling Module: Installation

All vehicles 

1. 1.
   
   Position the cooling module in the vehicle and install the cooling module bolts.
   • Tighten to 25 Nm (18 lb-ft).

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1. 2.
   
   Connect the ambient temperature sensor electrical connector and harness retainer.

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1. 3.
   
   Connect the horn assembly electrical connector.

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1. 4.
   
   Using new O-ring seals and gaskets, connect the A/C condenser outlet and inlet fittings and install the nut and bolt.
   • Tighten to 15 Nm (133 lb-in).

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Vehicles without an auxiliary transmission cooler 

1. 5.
   
   Install the transmission cooler tube pin-type retainer. Connect the transmission fluid cooler hoses to the radiator and position the clamps.

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Vehicles with an auxiliary transmission cooler 

1. 6.
   
   Connect the transmission fluid cooler hoses to the auxiliary transmission cooler and the radiator and position the clamps.

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All vehicles 

1. 7.
   
   Remove the pin-type retainers and the RH air deflector.

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1. 8.
   
   
   NOTE: Horn not shown for clarity.

   Remove the pin-type retainers and the LH air deflector.

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1. 9.
   
   
   NOTE: Navigator shown Expedition similar

   Install the hood latch assembly bolts and connect the hood latch cable retainer.

   • Tighten to 25 Nm (18 lb-ft).

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1. 10.
   
   Connect the lower radiator hose and install the spring clip.

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1. 11.
   
   Connect the radiator overflow hose and position the clamp.

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1. 12.
   
   Position the wiring harness and attach the BJB to the bracket. Attach the wiring harness retainer to the LH side of the cooling fan motor and shroud.

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1. 13.
   
   Attach the wiring harness retainer to the LH side of the cooing fan motor and shroud.

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1. 14.
   
   Attach the cooling fan wiring harness retainers to the cooling fan shroud and connect the cooling fan motor electrical connectors.

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1. 15.
   
   Attach the wiring harness retainers to the RH side of the cooling fan motor and shroud.

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1. 16.
   
   Attach the wiring harness retainer and the electrical connector retainer to the top RH side of the cooling fan motor and shroud.

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1. 17.
   
   Connect the upper radiator hose to the radiator and position the clamp.

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1. 18.
   
   Connect the battery power cable terminals and install the nut.
   • Tighten to 10 Nm (89 lb-in).

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1. 19.
   
   Close the BJB cover.

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1. 20.
   
   Install the front bumper cover. For additional information, refer to Bumpers .

1. 21.
   
   Install the RH and LH headlamp assemblies. For additional information, refer to Exterior Lighting .

1. 22.
   
   Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables .

1. 23.
   
   Fill and bleed the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding .

1. 24.
   
   Fill the transmission with fluid and verify correct operation. For additional information, refer to Automatic Transmission 6R80 .

1. 25.
   
   Evacuate, leak test and charge the refrigerant system. For additional information, refer to Climate Control System General Information .