Ford Thunderbird Manual page 223

03-03- 13
DIAGNOSIS AND TESTING (Continued)
Radiator Leak Test, Removed from Vehicle
CAUTION: Do not leak-test an aluminum radiator
in the same water that copper /brass radiators
are tested in. Flux and caustic cleaners may be
present in the tank and will damage aluminum. A
separate clean test tank is necessary for
aluminum radiators. If conditions do not allow a
separate tank for aluminum radiator leak testing,
thoroughly clean the test tank each time before
testing an aluminum radiator in the tank.
Clean the radiator before leak-testing to prevent
contaminating the test tank. Leak-test the radiator in
clean water with 1 38 kPa (20 psi) air pressure.
Always install plugs in the transmission oil cooler
fittings before leak-testing or cleaning any radiator for
a vehicle with an automatic transmission.
REMOVAL AND INSTALLATION
Thermostat, Water
Removal
1 . Partially drain the cooling system so that the
coolant level is below the water thermostat
(8575).
2. Disconnect upper radiator hose (8260) at the
water hose connection (8592).
3. Remove two water outlet connection retaining
bolts and remove water hose connection and
water hose connection gasket (8255).
Installation
1 . Clean sealing surface on water hose connection
and on intake manifold (9424).
2. NOTE: To prevent incorrect installation of the
water thermostat, the water hose connection on
all engines contains an alignment slot which the
water thermostat assembly fits it. Install the
water thermostat with the bridge section in the
water hose connection. Turn the water
thermostat clockwise to lock it in position on the
flats cast into the water hose connection.
Position water thermostat, and water hose
connection on the intake manifold. Install the two
retaining bolts and tighten to 8- 1 2 N·m (7 1 - 1 06
lb-in).
3. Connect upper radiator hose to water hose
connection. Move new hose clamp to water hose
connection. Make sure clamp is between
alignment marks on hose.
Fill cooling system with a 50 I 50 mixture of
4.
Premium Cooling System Fluid E2FZ- 1 9549-AA
or -8 (in Oregon, F5FZ- 1 9549-CC; in Canada,
CXC-8-8), recycled coolant or equivalent meeting
Ford specification ESE-M97844-A.
Engine Cooling
5. Start engine and check all hoses and connections
for leaks.
Thermostat lnstallation - 3.8L Engine Shown, 4.6L
Engine Similar
Water Pump
Refer to Section 03-0 1 A (3.8L) or Section 03-Q 1 8
(4.6L).
Radiator Hoses
Removal
Drain the radiator (8005) as described. Loosen the
clamps at each end of the hose to be removed. Slide
the hose off the radiator connection and the water
hose connection (8592)(upper radiator hose (8260))
or the water pump connection (lower radiator hose
(8286)).
Installation
CAUTION: Make sure the clamps are beyond the
bead and place in the center of the clamping
surface of the connections. New screw-type hose
clamps must be Installed Inside the hose
alignment marks.
Position the clamps at least 50 mm (2 inches) from
each end of hose and slide hose on the connections.
lighten clamp to 2.2-3.4 N·m (2Q-30 lb-in) (when using
screw-type clamps). Fill the cooling system with a
50 I 50 mixture of Premium Cooling System Fluid
E2FZ - 1 9549-AA or -8 (in Oregon, F5FZ - 1 9549-GC; in
Canada, CXC-8-8), recycled coolant or equivalent
meeting Ford specification ESE-M97844-A and water.
Operate the engine for several minutes then check the
hoses and connections for leaks.
03-03- 1 3
WATER OUTLET
8594
AND SLOT
THERMOSTAT AND
0-RING ASSY
8A570
85202-A
1997 Thunderbird, Cougar July 1 996