Attachment III - Technical Information

OVERVIEW

This program involves replacing the blow-molded (plastic) charge air cooler (CAC) cold-side duct with a metal duct with rubber cuffs at each end. This duct is located on the left (driver) side of the engine compartment and is connected between the charge air cooler outlet and the intake manifold.

SERVICE PROCEDURE

1. Remove the air filter cartridge and both the air filter inlet and outlet tubes.





2. Loosen the clamps at both ends of the blow-molded CAC duct. Remove the duct and clamps then discard. See Figure 1.

3. Using Motorcraft Metal Brake Parts Cleaner PM-4, thoroughly clean the CAC outlet port and intake manifold inlet port of any oil residue or dirt that would interfere with an air-tight seal.

4. CAUTION: When installing and tightening the clamps near the intake manifold on the new CAC duct, be sure to position them so they do not come in contact with the hood.





Install the new CAC duct and rubber cuffs. Tighten the clamps to 12 Nm (9 lb-ft). See Figure 2.

5. Reinstall the air filter inlet and outlet tubes and the air filter cartridge.

[NEW] ROAD TEST PROCEDURE

Refer to the Road Test Procedure in Emission Recall 05E15. This road test is to be performed only once per vehicle and only after all applicable recall and service programs have been completed.