Well I was able to get started today. It is going to take about a week to get everything done sine I only have a few hours in the evenings to get any work done. I am doing all of the install on my own, on my back, in my garage, with the car up on jack stands. Is it ideal,no. Is it worth it, yes, because I love doing it and I get the satisfaction of knowing I did it. Not to mention the piece of mind knowing there were no cutting corners. I decided to start off with the Heat exchanger.
First and foremost the battery is disconnected and for this round of mods it and the battery tray are removed. This allows for easier access to the header bolts and EGR valve where it connects to the passenger side header (for the header install to come):
For access to the HE the front bumper cover has to be removed. All under carriage splash guards have to be removed:
The front wheels are removed. There are 2 bolts and 1 screw on each side of the bumper in the fender well that have to be taken out along with 4-5 of Ford's favorite plastic push plugs in order to remove the wheel well splash guards.
There are no bolts at the top of the fender where the bumper cover meets the front fender (like on the 05-09 cars) pulling with steady pressure straight back (do not jerk), you will find that there are 3 clips that will pop loose. Next remove the radiator cover and the last remaining bolts securing the bumper cover across the top. Be sure to unplug all marker lights, fog lights, horn, and outside air temp sensor. The Afco instructions have you remove the front splitter; this is not necessary.
Following the removal of the front bumper the Afco instructions are very detailed and self explanatory. I will say I do not know how the get some of their hose clamps (squeeze style) on at the factory but they sure put then in a position where squeezing them is an extreme pain in the ass.
Size difference in the Afco unit and the stock HE. This should help a lot.
And finally installed. This took about 3 hours (bumper has not been reinstalled yet) as it was extremely hot outside and I am very meticulous. Only basic hand tools are required.