Thermostat: Service and Repair

REMOVAL

WARNING: NEVER REMOVE THE RADIATOR CAP (8100) UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR (8005), USE EXTREME CARE WHEN REMOVING THE RADIATOR CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.

1. Partially drain the engine coolant so that the engine coolant level is below the water thermostat (8575).
2. Disconnect upper radiator hose (8260) at the water hose connection (8592).
3. Remove two water outlet connection retaining bolts and remove water hose connection and water hose connection gasket (8255).

INSTALLATION
1. Clean sealing surface on water hose connection and on intake manifold (9424).

NOTE: To prevent incorrect installation of the water thermostat, the water hose connection on all engines contains a locking slot which the water thermostat fits. Install the water thermostat with the bridge section in the water hose connection.

2. Position water thermostat, water hose connection gasket and water hose connection on the intake manifold. Install the two retaining bolts and tighten to 8-11 Nm (71-97 inch lbs.).
3. Connect upper radiator hose to water hose connection. Move new hose clamp to water hose connection. Make sure clamp is between alignment marks on hose.
4. Fill coolant with the recommended Premium Cooling System Fluid E2FZ-19549-AA or -B, in Oregon F5FZ-19549-CC, in Canada, Motorcraft CXC-8-B or equivalent meeting Ford specification ESE-M97B44-A.
5. Start engine and check all hoses and connections for leaks.
6. Stop the engine and allow to cool. Top off radiator coolant recovery reservoir (8A080) as required to maintain minimum cold fill level.