Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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The cooling system components include the: block heater (optional) cylinder head temperature sensor fan blade, fan motor and fan shroud assembly radiator pressure relief cap degas bottle radiator draincock water pump oil cooler (optional) water thermostat The water thermostat: controls the engine coolant temperature. allows quicker engine warm-up. The degas bottle: provides a location for system fill. contains coolant expansion and system pressurization. provides air separation during operation. replenishes the engine coolant to the system. The fan blade draws air through the radiator to help cool the engine coolant. The fan motor: operates only when the engine is running. will not operate when the engine is off. The engine coolant flows: from the lower radiator hose to the water pump. from the water pump to the engine block and the cylinder heads. A closed water thermostat returns the engine coolant to the water pump. An open water thermostat allows the engine coolant to flow to the radiator. Unsatisfactory coolant materials: Alcohol-type antifreeze does not provide adequate water pump lubrication. has lower boiling point reduced antifreeze protection Alkaline brine solutions will cause serious engine cooling system damage. The cylinder head temperature sensor provides a signal to the temperature gauge. will invoke failsafe cooling. The optional block heater: electrical heating element is installed in the block cooling jacket. uses a standard 110V (220V in Europe) electrical supply keeps the engine coolant warm during cold weather. The auxiliary water pump (3.9L only): provides heater coolant flow boost. has a secondary function of providing engine-off cooling. Coolant Flow 3.9L

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. Drain the engine coolant. For additional information, refer to Section 303-03. 2. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01. 3. Remove the engine anti-roll strut brace. Remove the nuts. Remove the brace. 4. Remove the engine anti-roll strut. Remove the bolts. 5. Remove the coolant expansion tank (8A080). For additional information, refer to Section 303-03. 6. Loosen the four water pump pulley bolts. 7. Remove the crankshaft damper (6316). For additional information, refer to Crankshaft Pulley in this section. 8. Disconnect the lower radiator hose. Reposition the clamp. Disconnect the hose.

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1. Drain the cooling system. Refer to the procedure in this section. 2. Remove the upper radiator hose bracket bolt and the upper radiator hose bracket. 3. Reposition the water bypass hose clamp and remove the water bypass hose (8597) from the water hose connection (8592) . 4. If equipped with A/C, remove the drier to evaporator liquid line bracket bolt and the drier to evaporator liquid line bracket to gain access to the water thermostat (8575) . 5. If equipped with A/C, remove the suction accumulator/drier bracket bolts and the suction accumulator/drier bracket. 6. If equipped with A/C, position the suction accumulator/drier (19C836) and drier to evaporator liquid line (19837) out of the way. 7. Remove the four water hose connection bolts and the water hose connection. 8. Remove the water thermostat from the thermostat housing. Installation 1. Clean the thermostat housing cover mating surface and groove of any remaining sealant. 2. Completely clean any coolant from these areas. 3. NOTE: Position the water hose connection on the thermostat housing within five minutes of applying the silicone sealant. Apply a continuous bead of silicone sealant to the inner surface and the perimeter of the water hose connection . The sealant should be 2.0-3.0mm (0.08-0.12 inch) wide on all sealing areas. 4. NOTE: When installing the water thermostat , ensure the jiggle valve is pointing upward.

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Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.0L engine may experience engine oil, transmission fluid or diesel fuel contaminating the cooling system. This flushing procedure is to be performed after the source of the cooling system contamination has been identified and repaired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow the steps in sequence to effectively repair the vehicle: • Drain cooling system contaminates. • Clean cooling system with Simple Green® Heavy Duty Cleaner and Degreaser. • Clean cooling system with Motorcraft® Engine Cooling System Iron Cleaner. NOTE ALL STEPS MUST BE COMPLETED IN ORDER TO PROPERLY CLEAN THE COOLING SYSTEM. ANY DEVIATION FROM THE SERVICE PROCEDURE WILL RESULT IN SHORTENED COOLANT PROTECTION AGAINST CORROSION IN THE COOLING SYSTEM. 1. Determine cooling system condition. Is the contaminated coolant in a flowable, liquid or milky state? a. No – Do not proceed as this procedure does not apply. (Non-Flushable Examples Figures 1-3)

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Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles, all equipped with a 6.0L engine, may exhibit: • Coolant venting from the degas bottle cap • No-crank/no-start • Coolant leak • White smoke from tail pipe • Low coolant • Lacks power overheat • No cabin heat The conditions typically occur when operating the vehicle under a load such as trailer towing, uphill driving, or both.SERVICE PROCEDURE Prior to making any repairs, verify the coolant level is not overfull. The new coolant fill level is at the “MIN” line of the degas bottle cold. Overfilled coolant levels will cause coolant to vent from the degas bottle cap. NOTE A FLOW CHART OF THIS PROCEDURE CAN BE FOUND AT THE END OF THE TSB. (FIGURES 9-11) Complete All Steps In Order As Outlined 1. Testing the degas bottle and pressure cap for proper operation of the pressure cap and its seal to the degas bottle: a. Do not remove the pressure cap. b. Install a pressure tester in-line with the degas bottle hose using Rotunda 014-R1068 adapter. (Figure 1)