Ford 6E5Z-8005-C Radiator Assembly

Whenever the turbocharger, charge air cooler, or cooler tubes are removed, always cover any opening to prevent debris from falling in, as the system is easily damaged; carefully clean all openings before reassembling. Begin by disconnecting the cable from the negative battery terminal. Lift the engine cover up and off the ball studs, then remove the cover. Raise the vehicle and support it securely on jackstands, then remove the under-vehicle splash shield. Drain the cooling system. Next, remove the coolant expansion tank and secure it out of the way. Release the hose clamps and detach the hoses from the pump, then disconnect the electrical connector from the pump. Remove the pump mounting bolts and lower the pump until the tab on the pump is free from the oil pan. Install the pump, ensuring the tab is aligned with the slot in the oil pan, then install and tighten the bolts to the specified torque. For the CAC radiator, remove the splash shield below the radiator to expose the lower support, then remove the lower support panel. Remove the CAC cover bolts and take the cover off from the bottom of the cooler. Disconnect the CAC Coolant Temperature sensor, loosen the clamps securing the inlet and outlet tubes to the CAC, and disconnect the tubes. Remove the CAC bolts and carefully lower the cooler down and out from under the vehicle; it may be necessary to remove the radiator mounting bolts from the top and support the radiator from above to create enough space for the charge air cooler. Installation is the reverse of removal, and remember to refill the cooling system.

Raise the vehicle, disconnect the negative battery cable, and remove the lower splash shield for most models. Detach the radiator hose and drain the cooling system. 1.5L and 1.6L engines come with a charge air cooler (CAC) and cooling fan/shroud assembly to be removed. 2012 and earlier models have radiators that are released from condensers while those of 2013 and later models are connected to condensers that can be removed. Automatic transaxle vehicles should have their transaxle cooler lines disconnected. The radiator should then be lifted out, checked for any leaks or damage, and cleaned. After cleaning, install it back ensuring that rubber insulators are well in place. Fill the coolant system, check for any leakage of fluids, and run the engine to break it in. Transmission fluid level on automatic transaxle-equipped vehicles shall be checked. Drain the cooling system, discharge air conditioning system, and remove the cooling module for 2.7L V6 models. Disconnect the upper radiator hose as well as the electrical connector to the cooling fans. Remove the cooling module while disassembling the radiator on 2.7L V6 models. Take off the front bumper cover, active shutter grille, engine cover. Remove the cooling fan shroud assembly; also disconnect transaxle cooler lines. Put in reverse order.