Cooling Module: Installation

All vehicles 

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

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• 3.
  
  Connect the horn assembly electrical connector.

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• 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 

• 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 

• 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 

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

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NOTE: Horn not shown in illustration for clarity.
• 8.
  Remove the pin-type retainers and the LH air deflector.

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NOTE: Navigator shown in illustration, Expedition similar
• 9.
  Install the hood latch assembly bolts and connect the hood latch cable retainer.
  • Tighten to 25 Nm (18 lb-ft).

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

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

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

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

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

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

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• 19.
  
  Close the BJB cover.

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

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

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

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

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

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