Water Bypass Tube

REMOVAL
1. Disconnect battery ground cable (14301).
2. Drain engine coolant.
3. Disconnect two center ignition wire separators (12297) from generator mounting bracket (10153).
4. Disconnect generator wiring harness positioning clip from generator mounting bracket.
5. Remove two bolts and two nuts attaching generator mounting bracket to generator (GEN)(10300) and upper intake manifold (9424).
6. Lift ignition wires and generator harness. Remove generator mounting bracket.
7. Disconnect water bypass tube to water thermostat housing hose and upper radiator hose (8260) at water bypass tube.
8. Disconnect fuel charging wiring (9D930) from both engine coolant temperature sensor and water temperature indicator sender unit connections at bottom of water bypass tube (8548). Remove engine coolant temperature sensor (ECT)(12A648) and water temperature indicator sender unit (10884) from water bypass tube if necessary.





9. Remove two retaining nuts from water bypass tube hold-down braces to intake manifold studs and remove water bypass tube.

INSTALLATION
1. Replace O-ring seals on water bypass tube as required. Replace center O-ring seal on water bypass tube if needed.

CAUTION: Do not cut O-ring seal during tube installation into cylinder heads (6049) as engine coolant leakage may occur.

2. Clean O-ring sealing surface on cylinder heads and coat water bypass tube sealing O-rings with a rubber lubricant meeting Ford specification ESE-M99B176-A. Insert water bypass tube support braces over intake manifold inner studs and press water bypass tube into position.
3. Install two water bypass tube retaining nuts and tighten to 8-12 Nm (71-106 inch lbs.).
4. if removed, install engine coolant temperature sensor and water temperature indicator sender unit onto the water bypass tube. Tighten to 16-22 Nm (12-17 ft. lbs.).
5. Connect fuel charging wiring to the ECT and water temperature indicator sender unit connectors.
6. Verify conductivity of water temperature indicator sender unit using Rotunda Digital Volt-Ohmmeter 014-00407 or equivalent. Touch body of water temperature indicator sender unit with probe and other probe to ground. If more than 1 ohm resistance, remove water bypass tube and remove paint on bottom of mounting tabs.
7. Connect water bypass tube to water thermostat housing hose and upper radiator hose at water bypass tube.
8. Position generator mounting bracket and install two front retaining bolts and two rear nuts. Tighten to 8-12 Nm (71-106 inch lbs.).
9. Connect generator wiring harness retaining clip to generator mounting bracket.
10. Position ignition wires and connect two ignition wire separators to generator mounting bracket.

CAUTION: Use extreme care to keep coolant mixture off of accessory drive pulleys. If needed, remove accessory drive belt (8620) and rinse with clear water. Clean pulleys and install drive belt. Drive belt squeal and early drive belt fatigue will occur otherwise.

11. Close radiator draincock (8115) and fill coolant.
12. Connect battery ground cable.
13. Start engine and check for leaks.