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Home >> Ford >> 2011 >> F 150 4WD V8-5.0L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Cooling System >> Radiator >> Service and Repair >> Cooling Module

Cooling Module




Cooling Module





Hood Latch, Transmission Cooler Tubes, Power Steering Cooler Tubes (6.2L) and Cooling Module Bolts









Wiring Harness and Power Steering Fluid Reservoir (6.2L)









Wiring Harness and Radiator Hose Retainers









Cooling Fan Wiring









Air Cleaner Element









A/C Fittings









Radiator Hoses - 3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L









Radiator Hoses - 6.2L









Removal

All engines

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding Cooling System Draining, Filling and Bleeding.

3. Evacuate the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

4. Disconnect the battery ground. For additional information, refer to Battery, Mounting and Cables Battery Disconnect.

5. Remove the headlights. For additional information, refer to Exterior Lighting Service and Repair.

6. Detach the LH hood latch cable retainer.





7. Detach the 2 RH hood latch cable retainers.





8. Remove the bolts and position the hood latch aside.





9. Remove the bolt, detach the hood latch release handle and the cable from the front bumper cover, and position the hood latch release handle aside.





10. Remove the front bumper cover. For additional information, refer to Bumpers Service and Repair.

11. Disconnect the horn electrical connector and detach the wiring harness and ambient temperature sensor retainers. Position the wiring harness aside.





12. Detach the wiring harness retainer from the RH side of the radiator grille support.





13. NOTE: RH shown, LH similar.

Disconnect the RH and LH front impact severity sensor electrical connectors and 2 wiring harness retainers. Position the wiring harnesses aside.





14. Release the clamp and disconnect the upper radiator hose from the radiator. Detach the radiator hose retainer from the cooling fan motor and shroud.

15. Remove the nut and detach the generator battery positive cable. Detach the 3 wiring harness retainers and position the wiring harness aside.





16. Remove the Air Cleaner (ACL) outlet tube. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

17. Disconnect the Mass Air Flow (MAF) sensor electrical connector.





18. Remove the ACL cover and the ACL element.

19. Remove the 6 pushpins and the upper radiator air deflector.





3.5L GTDI, 3.7L and 5.0L engines

20. Detach the wiring harness retainer from the stud bolt.

6.2L engines

21. Detach the power steering fluid cooler hose retainer and position the hose aside.

22. Release the clamp and disconnect the power steering fluid cooler hose from the power steering cooler.





23. Detach the wiring harness retainer from the power steering fluid reservoir stud bolt.

24. Remove the power steering fluid reservoir stud bolt.

All engines

25. If equipped, cut the block heater tie strap.

26. Remove the bolt and nut, and disconnect the A/C tube fittings from the A/C condenser. Discard the O-ring seals and gasket seals.

27. Disconnect the 2 cooling fan electrical connectors and detach the 3 cooling fan wiring harness retainers.

28. Release the 4 Power Distribution Box (PDB) retaining tabs and detach the PDB from the bracket. Detach the 1 LH and 3 RH wiring harness retainers and position the PDB, the wiring harness aside and the power steering fluid reservoir aside.

3.5L GTDI, 3.7L and 5.0L engines

29. Release the clamp and disconnect the radiator-to-degas bottle hose from the radiator.

30. 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.





6.2L engines

31. Remove the spring clip and disconnect the lower radiator hose from the radiator.

32. Disconnect the radiator overflow hose from the radiator.

All engines

33. Remove the 3 front air deflector-to-bumper pushpins.





34. Remove the 2 RH air deflector-to-frame rail pushpins.





35. Remove the 2 LH air deflector-to-frame rail pushpins.





36. Remove the 2 transmission cooler tube latch assemblies.

37. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes from the cooling module.





6.2L engines

38. Disconnect the power steering cooler-to-power steering fluid reservoir hose from the power steering fluid reservoir.





All engines

39. Remove the 6 cooling module bolts.

40. Remove the cooling module.

Installation

All engines

1. Position the cooling module into the vehicle.

2. Install the 6 cooling module bolts.
- Tighten to 30 Nm (22 lb-ft).

6.2L engines

3. Connect the power steering cooler-to-power steering fluid reservoir hose at the power steering reservoir.





All vehicles

4. Connect the transmission cooler tubes to the cooling module.

5. Install the transmission cooler tube latch assemblies.

6. Install the 2 LH air deflector-to-frame rail pushpins.





7. Install the 2 RH air deflector-to-frame rail pushpins.





8. Install the 3 front air deflector-to-bumper pushpins.





3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L engines

9. Push the spring clip in place and connect the lower radiator hose quick connect coupling to the radiator, making sure the coupling is secure.

10. Connect the radiator-to-degas bottle hose to the radiator and position the clamp.

6.2L engines

11. Connect the radiator overflow hose to the radiator.

12. Connect the lower radiator hose to the radiator and install the spring clip.

All engines

13. Position the PDB and wiring harness into place and connect the PDB retaining tabs. Attach the 1 LH and 3 RH wiring retainers.

14. Attach the 3 cooling fan wiring harness retainers and connect the 2 cooling fan electrical connectors.

15. Install new O-ring seal and gasket seal kits on the A/C condenser fittings.

16. Connect the A/C fittings to the A/C condenser and install the bolt and nut.
- Tighten to 15 Nm (133 lb-in).

17. If equipped, install a new block heater tie strap.

3.5L GTDI, 3.7L and 5.0L engines

18. Attach the wiring harness retainer to the stud bolt.

6.2L engines

19. Position the power steering fluid reservoir and install the stud bolt.
- Tighten to 11 Nm (97 lb-in).

20. Connect the wiring harness retainer onto the power steering fluid reservoir stud bolt.

21. Connect the power steering fluid cooler hose to the power steering cooler and position the clamp.





22. Connect the power steering fluid cooler hose retainer.

All engines

23. Install the upper radiator air deflector and install the 6 pushpins.





24. Install the ACL element and ACL cover.

25. Connect the MAF sensor electrical connector.

26. Install the ACL outlet tube. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.

27. Position the wiring harness and attach the 3 wiring harness retainers. Attach the generator battery positive cable and install the nut.
- Tighten to 9 Nm (80 lb-in).





28. Connect the upper radiator hose to the radiator and install the clamp. Attach the radiator hose retainer to the cooling fan motor and shroud.

29. NOTE: RH shown, LH similar.

Position the wiring harness into place and connect the RH and LH front impact severity sensor electrical connectors and wiring harness pushpin retainers.





30. Attach the wiring harness retainer to the RH side of the radiator grille support.





31. Position the wiring harness into place and connect the horn and ambient temperature sensor electrical connectors and attach the pushpin retainer.





32. Install the front bumper cover. For additional information, refer to Bumpers Service and Repair.

33. Position and attach the hood latch release handle and cable onto the front bumper cover and install the bolt.





34. Position the hood latch into place and install the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





35. Install the 2 RH hood latch cable pushpin retainers.





36. Install the LH hood latch cable pushpin retainers.





37. Install the headlights. For additional information, refer to Exterior Lighting Service and Repair.

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

39. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding Cooling System Draining, Filling and Bleeding.

40. Recharge the A/C system. For additional information, refer to Climate Control System - General Information and Diagnostics Air Conditioning (A/C) System Recovery, Evacuation and Charging.

41. Fill the power steering system. For additional information, refer to Steering System - Hydraulic Power Assist Steering (HPAS) Power Steering System Filling.

42. Check the transmission fluid and fill as necessary. For additional information, refer to Automatic Transaxle/Transmission - 6R80 Transmission Fluid Level Check and Transmission Fluid Drain and Refill.

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