Ford Thunderbird Manual page 220

03-03- 10
DIAGNOSIS AND TESTING (Continued)
Component Tests
Pressure Test-3.8L Engine
1 . Turn the engine OFF.
2. WARNING: NEVER REMOVE THE RADIATOR
CAP OR VENT PLUG 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,
RADIATOR COOLANT RECOVERY
RESERVOIR OR VENT, USE EXTREME CARE
WHEN REMOVING THE RADIATOR CAP OR
VENT PLUG FROM THE VEHICLE. 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.
Check engine coolant level as described and
reinstall radiator cap.
3. NOTE: With the radiator cap installed and the
cooling system pressure relieved, only a small
amount of coolant will be lost when the water
temperature indicator sender unit ( 1 0884) is
removed.
Disconnect the electrical connector from the
water temperature indicator sender unit, Remove
the water temperature indicator sender unit from
the engine.
4. Install the adapter fitting from Rotunda
Radiator I Heater Core Pressure Tester
0 1 4-R 1 072 or equivalent (male thread on one end
and hose connector on the other end to
accommodate the tester hose) tightly into the
intake manifold (9424) or cylinder head (6049) in
place of the water temperature indicator sender
unit.
5. Disconnect radiator overflow hose (8075) from
the radiator. Install a separate hose, making sure
hose is firmly installed on the radiator overflow
nipple and is in good condition. Insert the free end
of the hose into a container of water.
Attach the pressure pump and gauge to the
6.
adapter fitting and pressurize to the lower limit.
No bubbles should appear in water container. If
the system is satisfactory at the lower limit,
gradually increase the system pressure until a
slight stream of bubbles appears in the water
container. This is the upper limit of the radiator
cap .
Replace any radiator cap that exceeds the
specified upper limit pressure without discharging
bubbles.
Engine Cooling
If the pressure relief cap does not hold pressure,
7.
remove and wash the radiator cap in clean water
to dislodge all foreign particles from the gaskets.
Check the sealing surface in the filler neck.
Then inspect the cam lock flanges on both sides
of the filler neck for maximum radiator cap
engagement.
CAUTION: If the pressure drops, check for
8.
leaks at the engine-to-heater core hoses,
engine-to-radiator hoses, bypass hose,
water valve hose {If applicable), water hose
connection gasket {8255}, radiator and
heater core, etc. Also refer to engine system
checks if a leak cannot be located in cooling
system. Any leaks which are found must be
corrected and system rechecked or possible
damage to the vehicle may occur.
Pressurize the cooling system as described in
Step 6 (using a radiator cap that operates within
the specified upper and lower pressure limits) and
observe the gauge reading for approximately two
minutes. Refer to Specifications. Pressure should
not drop during this time.
If the system holds pressure, proceed to Step 9.
9. Release system pressure by loosening the
radiator cap and remove the adapter. Re-install
the water temperature indicator sender unit.
Check engine coolant level and replenish if
necessary with a 50 I 50 mixture of Premium
Cooling System Fluid E2FZ - 1 9549-AA or -B (in
Oregon, F5FZ- 1 9549-CC; in Canada, CXC-8-B),
recycled coolant or equivalent meeting Ford
specification ESE-M97B44-A and water.
Pressure Test-4.6L {2V) Engine
Turn the engine OFF.
1 .
2. WARNING: NEVER REMOVE THE RADIATOR
CAP OR VENT PLUG 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 COOLING
SYSTEM, NEVER REMOVE THE PRESSURE
RELIEF CAP FROM A HOT DEGAS BOTTLE.
WAIT UNTIL THE ENGINE HAS COOLED.
THEN WRAP A THICK CLOTH AROUND THE
PRESSURE RELIEF CAP AND TURN IT
SLOWLY ONE TURN
{COUNTERCLOCKWISE). STEP BACK WHILE
THE PRESSURE IS RELEASED FROM THE
COOLING SYSTEM. WHEN CERTAIN ALL THE
PRESSURE HAS BEEN RELEASED, REMOVE
PRESSURE RELIEF CAP {STILL WITH A
CLOTH).
Check engine coolant level as described.
03-03-1 0
1997 Thunderbird. Cougar July 1996