Cooling module — removal and installation Ford F150
Warning: The air conditioning system is under high pressure. DO NOT loosen any fittings or remove any components until after the system has been discharged. Air conditioning refrigerant should be properly discharged into an EPA-approved container at a dealer service department or an automotive air conditioning repair facility. Always wear eye protection when disconnecting air conditioning system fittings.
Warning: The engine must be completely cool when this procedure is performed.
Note: The cooling module consists of the radiator, air conditioning condenser and transmission fluid cooler. These components can all be removed as a unit for certain procedures where improved access to the front of the engine is required.
1. Have the air conditioning system discharged by a licensed air conditioning technician.
2. Drain the cooling system (see Tune-up and routine maintenance).
3. Remove the air filter housing and outlet pipe.
4. Remove the expansion tank mounting bolts and move the tank out of the way without disconnecting the hoses.
5. Disconnect the electrical connectors to the fan motors and the wiring harness retainers from the shroud.
6. Remove both headlight housings (see Chassis electrical system).
7. Remove the grille (see Body).
8. Remove the hood latch and cable (see Body).
9. Remove the side air deflector push-pins and remove the side air deflectors (see Radiator – removal and installation).
10. Remove the lower air deflector pushpins and remove the air deflector from the front bumper.
11. Disconnect the electrical connector and remove the connector bracket bolt from the frame. Then disconnect the electrical connector horn and impact sensors and move the harness out of the way.
12. Disconnect the lines to the condenser (see Air conditioning condenser – removal and installation).
13. Disconnect the hoses to the radiator (see Radiator – removal and installation).
14. Disconnect the transmission cooler line brackets and quick-connect couplings (V6 models) or standard spring clamps (V8 models) then separate the lines (see Automatic transmission).
15. Disconnect the electrical connectors at the shroud, to the charge air cooler (CAC) (see Fuel and exhaust systems) and impact sensors (see Chassis electrical system).
Cooling module mounting bolt locations (left-side shown, right side identical)
16. Remove the cooling module nuts and bolts (see illustration).
17. With the help of an assistant, remove the cooling module.
18. Installation is the reverse of removal. When installing the module, tighten the fasteners to the torque listed in this Chapter’s Specifications.
19. Fill the system with the proper mixture of antifreeze, and also check the automatic transmission and power steering fluid levels.
20. Start the engine and allow it to reach normal operating temperature, then check for leaks.
21. Have the air conditioning system recharged by the shop that discharged it.