OEM Ford F-150 Intercooler

Ford F-150 Intercooler Parts and Q&A

• Intercooler
  XL3Z-8K226-AA
  Q: How to service and repair the front intercooler and supercharger coolant pump on Ford F-150?

  A:

  Service and repair of the supercharger coolant pump as well as the intercooler starts with disconnecting the battery ground cable. The service area should be cleaned where the supercharger assembly exists while open engine and supercharger openings require protection from contamination. Procedures begin with tube removal of the air cleaner outlet followed by complete disconnection of the TP sensor along with the idle air control system electrical connectors and vacuum lines and vent hose. The throttle control linkages including speed control actuator cable and Accelerator Cable should be disconnected and then remove the throttle return spring keeping track of its correct position for refitting. First remove three nuts to reposition the accelerator cable bracket before disconnection of EGR Valve combined with its vacuum line and tube fitting. To proceed disconnect the brake booster vacuum line, take out the bracket bolt and separate another vacuum line. Take off the throttle body spacer by removing its bolts and throw away the gasket before proceeding to remove the accessory Drive Belt. Empty the Intercooling (IC) system coolant before unclamping and removing its hoses. Removing the IC water supply and return tubes nuts allows you to position their placement aside while also removing the EGR vacuum regulator bracket along with its nuts. First detach the two upper vacuum hoses from the actuator of the supercharger bypass valve before taking off the supercharger assembly with plenum along with the gasket for disposal. Proceed with upper intake manifold removal after discarding the vacuum hose and IC hoses and bolts because the gasket must also be discarded. You should discard the IC by removing both bolts and the IC element together with its gasket. To install the system first add the IC along with new gasket material and new bolts because new bolts serve as a requirement for installation. Begin with loosely installing four rear bolts into the upper intake manifold before you put on new IC hoses and gasket followed by attaching the vacuum hose. Moisten the new gasket for the supercharger and plenum assembly before installing it onto the engine. Tighten the bolts by following the sequence instructions while starting with 2 Nm (18 Lb-In) torques and then increasing to 45 Nm (33 Lb-Ft). The supercharger bypass valve actuator receives its two upper vacuum hoses while the EGR vacuum regulator bracket connects with its nuts and you should position the IC water supply tubes before installing the IC hoses with clamps. The procedure involves filling the IC cooling system before installing the accessory drive belt and placing a new gasket on the throttle body spacer. Bolt implementation should start with 10 Nm (89 Lb-In) torque followed by another 90-degree turn while ensuring proper sealing surface cleaning. Check for any damage or wear in the throttle body spacer gasket then perform a replacement when needed. Follow protocol to connect the vacuum lines with the brake booster vacuum line and EGR valve vacuum line as well as its tube fitting and accelerate cable bracket bolts. Next attach the throttle control linkages then reinstall them in the correct position of the throttle return spring before attaching vacuum lines and vent hose. After completing the previous steps users should reconnect both the idle control and TP sensor electrical connectors and then install their air cleaner outlet tube before reconnecting the battery ground cable.