Supplement # 5 - Attachment III
AFFECTED VEHICLES1996-1997 TAURUS AND SABLE EQUIPPED WITH 3.OL VULCAN GASOLINE AND ETHANOL ENGINES
RECOMMENDED SUPPLIES -- FLUSH PROCEDURE
The components shown are referenced throughout the technical instructions to facilitate the flush procedures. The picture representation and sizes are provided for your reference. For additional or replacement items, procure locally as required.
INSPECTION
1. Check for presence of coolant by-pass hose, shown in Figure 2, then proceed to Service Procedure.
SERVICE PROCEDURE
1. Raise and support vehicle.
2. Remove splash shield.
3. Lower vehicle.
4. Remove radiator draincock, then completely drain and discard cooling system fluid.
5. Loosen alternator brace retaining nuts, then position brace away from heater return hose. Refer to Figure 3.
6. Remove heater return hose from the water pump fitting and discard clamp. See Figure 3.
NOTE:
If coolant by-pass hose has already been installed, proceed to step 8.
7. Install coolant by-pass hose as follows:
^ Remove clean air tube.
^ Remove coolant recovery hose from fitting shown in Figure 4 and discard clamp.
^ With suitable driver, represented in Figure 5, install restrictor insert (-8N030-) as shown in Figure 6. Restrictor insert must be installed flush to shoulder on coolant recovery fitting. It is acceptable if restrictor insert is loose in fitting.
^ Install new screw clamp (376240-S100) on coolant recovery hose.Reinstall coolant recovery hose and tighten clamp.
^ Remove heater hose from the heater core return tube.
^ Remove fuel vapor hose clip from stud on dash panel. Install new clip and fuel vapor hose clip on stud. Install and tighten new (N621906-S36) nut. See Figure 7.
^ Install coolant by-pass hose at heater core return tube connection, located at dash panel. See Figure 8.
^ Remove heater supply hose from lower intake manifold and discard clamp. See Figure 9.
NOTE:
The "H" marking on hose must be in straight-up position.
^ Install coolant by-pass hose to lower intake manifold heater supply fitting and install clamp inside "H" marking. Refer to Figures 8 and 9.
NOTE:
Check by-pass hose assembly for possible kinks or possible interference with transmission dipstick and ETA check valve.
^ Cut heater supply hose approximately 8-1/2 inches from original connection at lower intake manifold. Install new screw clamp (389772-S100) on remaining heater supply hose. Install heater supply hose to "Tee" on coolant by-pass hose and tighten clamp. Refer to Figure 9.
^ Reinstall clean air tube.
^ Insert new coolant by-pass hose into new clip on dash panel. See Figure 10.
8. Disconnect upper radiator hose from thermostat housing and discard clamp.
9. Using clamping pliers, clamp off coolant by-pass hose at center of hose. See Figure 11.
10. Raise and support vehicle.
11. Remove engine block core plug located next to the oil filter. On the opposite side of the engine block, there are two core plugs; remove the engine block core plug closest to the water pump.
12. Remove lower radiator support bracket that covers lower radiator hose.
13. Remove lower radiator hose from radiator and discard clamp.
14. Clean core plug bores in cylinder block with sand paper drum (Fine 150-grit 1.5" dia.). Ensure all Loctite(R) and rust is removed from core plug bore.
15. Lower vehicle.
16. Push vehicle to flushing station.
17. Connect garden hose to heater return hose using adapter. See Figure 12.
18. Turn garden hose on full pressure.
19. Flush engine/heater core for ten (10) minutes. Water will drain out of core plug holes.
20. Disconnect garden hose from heater return hose.
21. Insert garden hose into upper radiator hose. See Figure 13.
22. Flush radiator for two (2) minutes. Water will drain out of lower radiator hose connection and draincock.
23. Remove garden hose from upper radiator hose.
24. Insert garden hose into coolant recovery bottle. See Figure 14.
25. Flush coolant recovery bottle for four (4) minutes. Water will drain out of lower radiator hose.
26. Remove garden hose from coolant recovery bottle. Let cooling system completely drain before proceeding to next step.
27. Push vehicle back to hoist.
28. Raise and support vehicle.
29. Lubricate 0-rings of new engine core plugs (-6C057-) with silicone dielectric grease (WA-10).
30. Install left and right bank front engine core plugs. Index dimples on the plugs to 12 o'clock position. Refer to Figure 15.
NOTE:
Do not over torque.
31. Tighten core plug retaining nuts to 3.2 Nm (28 lb/in). See Figure 15. Use of 1/4" drive, 8 mm flex socket with a long extension is acceptable. Make sure plugs do not rotate when tightening retaining nut.
32. Install new screw clamp (383525-S) on lower radiator hose. Connect lower radiator hose to radiator and tighten clamp.
33. Install lower radiator support bracket.
34. Install and tighten radiator draincock.
35. Lower vehicle.
36. Turn heater and blower switches to OFF position.
37. Remove clamping pliers from coolant by-pass hose.
38. Install new screw clamp (383525-S) on upper radiator hose. Connect upper radiator hose to thermostat housing and tighten clamp.
39. WARNING: WEAR RUBBER GLOVES DURING THIS STEP. CHEMICAL CLEANER USED MAY CAUSE SKIN IRRITATION. DO NOT add chemical cleaner to the coolant recovery bottle. Using funnel, slowly add one (1) bottle of chemical cleaner (-19A503-) into HEATER RETURN HOSE. See Figure 16.
40. Connect and clamp the heater return hose to water pump fitting.
41. Slowly fill cooling system with water. Squeeze upper radiator hose to purge air from system as water is added. Coolant level must be filled to the top of the clear portion of the coolant recovery bottle to completely clean the coolant recovery bottle.
42. Start engine and rev to 2000 RPM for one (1) minute. Do not exceed 2500 RPM.
43. Check cooling system for leaks.
44. Recheck coolant level. Using water, bring level to top of clear portion of coolant recovery bottle, if necessary.
45. Install coolant pressure relief cap.
46. Run engine at idle until upper radiator hose is hot (when thermostat opens) approximately 12 minutes.
47. Turn engine off and let chemical solution soak for a minimum of thirty (30) minutes, while engine cools.
48. WARNING: COOLANT MAY BE HOT. Remove coolant pressure relief cap.
49. Partially raise vehicle.
50. WARNING: WEAR RUBBER GLOVES DURING THIS STEP. CHEMICAL CLEANER USED MAY CAUSE SKIN IRRITATION. Remove radiator draincock.
51. Completely drain chemical solution from cooling system and discard.
52. Lower vehicle.
53. Unclamp and disconnect heater return hose from water pump fitting.
54. Install a 3/4" I.D. rubber cap on the water pump heater hose fitting. See Figure 17.
55. Disconnect and plug radiator overflow hose from coolant recovery bottle. Discard clamp. Refer to Figure 18.
56. Install coolant pressure relief cap.
57. Attach 4 foot section of 3/8-inch vinyl hose to overflow fitting on coolant recovery bottle. See Figure 18. Let vinyl hose hang over fender.
58. Push vehicle to flushing station.
59. Connect garden hose to heater return hose using adapter.
60. Turn garden hose on full pressure.
61. With engine off, flush engine for five (5) minutes. Water will drain out of radiator draincock hole and 4 ft. hose attached to coolant recovery bottle.
62. Turn garden hose off and remove coolant pressure relief cap from coolant recovery bottle.
63. Disconnect garden hose from heater hose. Let cooling system completely drain before proceeding to next step.
64. Push vehicle back to hoist.
65. Raise and support vehicle.
66. Install and tighten radiator draincock.
67. Install splash shield.
68. Lower vehicle.
69. Remove rubber cap from the water pump heater hose fitting.
70. If vehicle had by-pass previously installed, install new screw clamp (388788-S), reconnect heater return hose to water pump and tighten clamp. If by-pass was Installed in the previous step, use constant tension clamp already installed on heater return hose. Connect and clamp the heater return hose to water pump fitting.
71. Reattach and secure alternator brace.
72. Remove 3/8-inch vinyl hose from coolant recovery bottle.
73. Unplug radiator overflow hose, then install new screw clamp (376240-S100). Reconnect radiator overflow hose to coolant recovery bottle and tighten clamp.
74. Add one (1) bottle (16 oz.) of Heavy Duty Cooling System Additive (FW-16) to coolant recovery bottle.
75. Add 6 quarts of new coolant (-19549-) to coolant recovery bottle. Fill remainder of cooling system with water to cold fill line on coolant recovery bottle.
76. Start engine and top off with water to cold fill line, if necessary.
NOTE:
This step must be done before thermostat opens.
77. Rev engine to 3000 RPM for 30 seconds, and check for foaming inside coolant recovery bottle. If foaming is present, turn off engine and refer to Coolant By-Pass Restrictor installation Procedure, as the coolant by-pass restrictor has not been installed.
78. Install coolant pressure relief cap.
79. Select maximum heater temperature and blower motor speed settings. Position control to discharge air at panel vent in instrument panel.
80. Start engine and allow to idle until normal operating temperature is reached. While engine is idling, feel for hot air at panel vents.
81. CAUTION: If air discharge remains cool and engine coolant temperature gauge does not move, engine coolant level is low and must be filled. Stop engine, allow to cool and fill cooling system as described. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from panel vents. The engine coolant temperature gauge should maintain a stabilized reading to within NORMAL range and upper radiator hose should feel hot to touch.
82. Shut engine off and allow to cool.
83. Check engine for coolant leaks.