Attachment III - Technical Information

OVERVIEW

This program is being supplemented to include replacement of the upper radiator hose clamps. Included in this supplement is:

^ additional information regarding access to clamps on certain vehicle/engine applications and,

^ clarification in the proper methods of breaking the adhesive bond and removing the clamps from the hoses without causing any damage.

SERVICE PROCEDURE

WARNING:
TO AVOID PERSONAL INJURY, DO NOT UNSCREW THE RADIATOR CAP WHILE THE ENGINE IS OPERATING OR HOT. THE COOLING SYSTEM IS UNDER PRESSURE; STEAM AND HOT LIQUID CAN COME OUT FORCEFULLY WHEN THE CAP IS LOOSENED SLIGHTLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.

CAUTION:
The coolant must be recovered in a suitable, clean container for reuse. Do not contaminate the coolant by mixing it with other coolants or draining it into a dirty container.

CAUTION:
All vehicles are filled with Motorcraft Premium Gold Engine Coolant VC-7-B (in Canada CVC-7-A) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same type coolant that is present in the system. Do not mix coolant types.

1. Make sure the engine is cool.

2. Wrap a thick cloth around the radiator cap. Slowly turn the cap counterclockwise (left) until the pressure begins to release.

3. Step back while the pressure releases.

4. When you are sure all the pressure has been released, use the cloth to turn and remove the cap.

5. Place a suitable clean container below the radiator draincock. Drain the coolant.

6. Tighten the radiator draincock when finished.

7. On 4.6L-equipped applications, remove the air cleaner outlet tube.

8. Loosen the tension on the hose clamps on the upper radiator hose and remove the hose from the radiator and the thermostat housing. Place the hose on a bench.

9. On 4.6L-equipped all wheel drive (AWD) applications, working from above the engine compartment with the vehicle on the ground, loosen the tension on the hose clamp on the lower hose at the water pump outlet. Then, remove the hose from the water pump outlet.

10. Raise the vehicle on a hoist.

11. With a drain pan positioned under the hose connection, loosen the tension on the hose clamp and remove the lower radiator hose from the radiator and water pump. Place the hose on a workbench.

12. WARNING: HEAT GUNS GET VERY HOT. WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT (PPE'S) WHEN HANDLING HEATED HOSE CLAMPS.

CAUTION:
Hose clamps are bonded to the radiator hose with a spot of adhesive located 180 degrees away from the clamp tangs. Do not attempt to pull the clamps oft the hoses without first heating the adhesive or damage to the hose may result.

CAUTION:
Do not use an open flame (butane torch, lighter, etc.) to heat the clamps or damage to the hose(s) may result. Also, DO NOT USE the flameless heat gun from the Rotunda Wire Splice Repair Kit. The concentrated heat may damage the hose. Use only a heat gun that produces a hot air flow to heat the clamps. Hose replacement is NOT covered under this program.

Using a heat gun, heat the adhesive for approximately 30 seconds or until the adhesive bond is broken and the clamps are loose, then remove and discard the clamps.

13. Install locally obtained screw-type hose clamps onto the hoses, then reinstall the lower hose onto the radiator and water pump (on 4.6L AWD applications, it is recommended that the lower hose be connected to the water pump while working from above the engine compartment with the vehicle on the ground). Tighten the clamps to approximately 5 Nm (44 lb-in).

14. Lower the hoist.

15. On 4.6L AWD applications, connect the lower radiator hose to the water pump.

16. Install the upper radiator hose to the radiator and the thermostat housing.

17. Tighten all hose clamps to 5 Nm (44 lb-in).

18. On 4.6L-equipped applications, install the air cleaner outlet tube.





19. Using the RADKITPLUS and following the RADKITPLUS manufacturer's instructions, bleed and fill the cooling system with the original coolant that was recovered in Step 5. By using the RADKITPLUS, no coolant top-off is necessary. See Figure 1.