Attachment III - Technical Information

Taurus/Sable 3.0L Engine Coolant Bypass Hose

Affected Vehicles:
1992, 93 & 94 Taurus and Sables equipped with 3.0L engines. (Does not include 3.0L SHO engines).

PARTS REQUIRED - ORDER AS REQUIRED

PART NUMBER DESCRIPTION QUANTITY

F4DZ-18472-A Hose, Heater to Engine Water Inlet 1

376240-S100 Clamp (can be obtained locally) 1

E2FZ-19549-AA or B CXC-8 Engine Coolant - up to 1 pint 1 pint
-B (in Canada)

Bypass Hose Replacement Service Procedure

1. Open door. Connect Rotunda Memory Saver 014-R1064 or equivalent.

2. Open the hood and place fender covers.

3. Disconnect battery negative cable.

WARNING
THE ENGINE RADIATOR ELECTRIC FAN MAY COME ON AT ANY TIME WITHOUT WARNING EVEN IF THE ENGINE IS NOT RUNNING. DISCONNECT THE NEGATIVE BATTERY CABLE BEFORE SERVICING.

4. Position drain pan below radiator.

WARNING
NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITION WHILE THE ENGINE IS RUNNING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, 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 PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE RADIATOR CAP (STILL WITH THE CLOTH), TURN AND REMOVE IT.

5. Remove radiator cap and open radiator draincock to drain coolant from radiator.

CAUTION
Care should be taken to ensure that the steel tube is not damaged. A mini hack saw or hack saw blade with an attached handle should be used.





6. Cut the crimped aluminum band which secures the heater bypass hose to the steel tube assembly. Refer to Figure 1.

7. Disconnect the lower end of the heater bypass hose from the engine nipple. Retain the constant tension clamp.

8. Place the hose clamps on the new bypass hose.





9. Install the bypass hose on the engine nipple and the bypass tube, refer to Figure 2.

10. Position the hose clamps past the upset bead on both the bypass tube and the engine nipple.

11. Tighten the 376240-S100 hose clamp to 1.7-2.4 Nm (15-21 lbs-in). See Figure 2.

12. Close the radiator draincock.

13. Refill cooling system with 50/50 mixture of Ford Premium Cooling System Fluid E2FZ-19549-AA or -B (in Canada, Motorcraft CXC-8-B) and water.

14. Connect the battery negative cable.

15. Remove Memory Saver.

16. Check and add coolant as required.

17. Start the engine and check for leaks.

18. Remove fender covers and close hood.