Engine Cooling Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Scheme 1

Note. The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

Walter C. Avrea, the owner of patents 3,601,181 and RE 27,965, has granted Ford Motor Company rights with respect to cooling systems covered by these patents.

The cooling system components are as follows

1. block heater
2. cylinder head temperature (CHT) sensor - 4.6L, 5.4L and 6.8L
3. engine coolant temperature (ECT) sensor - 6.0L Diesel
4. fan blade
5. fan clutch
6. fan shroud
7. cooling fan stator - 6.0L Diesel
8. vistronic fan clutch - 6.0L Diesel
9. radiator
10. pressure relief cap
11. degas bottle
12. radiator draincock
13. coolant pump
14. thermostat

The radiator allows excess engine heat to be transferred to the air.

The radiator cannot be serviced. Install a new radiator.

The coolant pump circulates the coolant. The thermostat

1. controls the engine coolant temperature.
2. allows quicker engine warm-up.

The degas bottle

1. provides a location for service fill.
2. contains coolant expansion and system pressurization.
3. provides air separation during operation.
4. replenishes the engine coolant to the system.

The fan blade draws air through the radiator to help cool the engine coolant.

On gasoline engines, the fan clutch is a thermostatically controlled clutch that controls the fan blade.

On the 6.0L diesel engine, the vistronic fan clutch is controlled by the powertrain control module (PCM). The PCM monitors engine oil temperature (EOT) and engine coolant temperature (ECT) and sends a duty cycle command to the fan clutch to achieve adequate cooling. When a circuit fault is detected, the PCM will set a DTC.

The engine coolant flows

1. from the lower radiator hose to the coolant pump.
2. from the coolant pump to the engine block and the cylinder heads.

A closed thermostat returns the engine coolant to the coolant pump. An open thermostat allows the engine coolant to flow to the radiator.

The optional block heater

1. contains an electrical heating element that is installed in the core plug opening. uses a standard 110-volt electrical supply
2. keeps the engine coolant warm during cold weather.

Special Tool(s)

SPECIAL TOOLS Radiator Pressure Tester 014-R1072 or equivalent 73 Digital Multimeter 105-R0051 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool Battery/Antifreeze Tester 014-R1060 or equivalent

Scheme 2

Scheme 3

Scheme 4

Inspection and Verification

1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply. ENGINE COOLING VISUAL INSPECTION CHART Mechanical Electrical Leaks Damaged hoses Loose/damaged hose clamps Damaged head gaskets Damaged intake manifold gasket Damaged coolant pump Damaged radiator Damaged degas bottle Damaged heater core Damaged fan/fan clutch Damaged engine coolant temperature sensor Damaged wiring
3. If the inspection reveals an obvious concern that can be readily identified, repair as necessary.
4. Inspect the coolant condition. Inspect the coolant color: If Motorcraft Premium Gold Engine Coolant VC-7-A (yellow color) or equivalent meeting Ford specification WSS-M97B51-A1 has a clear or pale yellow color, this indicates higher water content than required. Dark brown could indicate unauthorized Stopleak may have been used. Use Cooling System Stop Leak Pellets VC-6 or equivalent meeting Ford specification WSS-M99B37-B6. A light or reddish brown color indicates that rust may be present in the cooling system. Flush the system and refill with the correct mixture of distilled water and Motorcraft Premium Gold Engine Coolant. An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For additional information on engine diagnosis, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) . A milky brown color may indicate that either engine oil or transmission fluid is entering the cooling system. If transmission fluid is suspected, the cause may be a leaky radiator. Pressure test the cooling system. For additional information, refer to «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) in this section. If engine oil is suspected, the cause of the leak may be internal to the engine. For additional information on engine diagnosis, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) . If transmission fluid is contaminated with engine coolant, the cause may be a leaky radiator. Pressure test the system. For additional information, refer to the «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) . If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the special tool. The freezing point should be in the range of -50°F to -10°F. If the vehicle is driven in cold climates (lower than -34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Maximum coolant concentration is 60/40. Minimum coolant concentration is 40/60. Adjust coolant range and level if necessary: If coolant is low, add specified coolant mixture only. If the engine coolant tests too weak, add straight engine coolant until the readings are within acceptable levels. If the engine coolant tests strong, remove some of the engine coolant and add distilled water until the readings are within acceptable levels.
5. If the concern remains after the inspection, determine the symptom(s). GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__symptom-chart) .

Symptom Chart

ENGINE COOLING SYMPTOM CHART

PINPOINT TEST A: LOSS OF COOLANT

1. A1 CHECK THE ENGINE COOLANT LEVEL WARNING: To avoid personal injury, do not unscrew the coolant pressure relief cap while the engine is operating or hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. NOTE: Allow the engine to cool before checking the engine coolant level. Key in OFF position. Visually check the engine coolant level at the degas bottle. Is the engine coolant level within specification? Yes : GO to A2. No : REFILL the engine coolant as necessary. GO to A2.
2. A2 CHECK THE PRESSURE RELIEF CAP WARNING: To avoid personal injury, do not unscrew the coolant pressure relief cap while the engine is operating or hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. NOTE: Allow the engine to cool before checking the engine coolant level. Carry out the pressure relief cap test. Refer to «PRESSURE TEST»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__pressure-test) . Is pressure relief cap OK? Yes : GO to A3. No : INSTALL a new pressure relief cap. TEST the system for normal operation.
3. A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK WARNING: To avoid personal injury, do not unscrew the coolant pressure relief cap while the engine is operating or hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Key in OFF position. Inspect the engine coolant in degas bottle for signs of transmission fluid or engine oil. Is oil or transmission fluid evident in coolant? Yes : If engine oil is evident, GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) . If transmission fluid is evident, INSTALL a new radiator. No : GO to A4.
4. A4 CHECK THE ENGINE AND THE TRANSMISSION FOR COOLANT Remove the oil level dipsticks from the engine and the transmission. Is coolant evident in oil or transmission fluid? Yes : If coolant is in engine, GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) . If coolant is in transmission, INSTALL a new radiator. No : GO to A5.
5. A5 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to the «COMPONENT TESTS»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) . Does the engine cooling system leak? Yes : REPAIR or INSTALL new components. TEST the system for normal operation. No : The cooling system is operational. GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__symptom-chart) .

PINPOINT TEST B: THE ENGINE OVERHEATS

1. B1 CHECK THE ENGINE COOLANT LEVEL WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, turn and remove the pressure relief cap (still with a cloth). NOTE: If the engine is hot, allow the engine to cool before proceeding. Key in OFF position. Make sure the engine is cool. Wrap a thick cloth around the coolant pressure relief cap on the degas bottle. Slowly turn the cap counterclockwise (left) until the pressure begins to release. Step back while the pressure releases. When you are sure all the pressure has been released, use the cloth to turn and remove the cap. Check the engine coolant level at the degas bottle. Is the engine coolant OK? Yes : GO to B2. No : REFILL the engine coolant at the degas bottle. GO to «PINPOINT TEST A»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__pinpoint-test-a-loss-of-coolant) .
2. B2 CHECK THE COOLANT CONDITION Check the coolant for rust, dirt or contamination. Is the coolant condition OK? Yes : GO to B3. No : FLUSH the engine cooling system; REFER to «COOLING SYSTEM FLUSHING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) . TEST the system for normal operation.
3. B3 CHECK FOR AN AIRFLOW OBSTRUCTION Inspect the A/C condenser core and radiator for obstructions such as leaves or dirt. Is there an obstruction? Yes : REMOVE the obstruction. CLEAN the A/C condenser core and radiator. TEST the system for normal operation. No : GO to B5 .
4. B4 CHECK THE THERMOSTAT OPERATION Start the engine and allow the engine to run for ten minutes. Feel the inlet and outlet heater hoses and the underside of the upper radiator hose. Are the upper radiator hose and the heater water hoses cold? Yes : INSTALL a new thermostat. TEST the system for normal operation. No : GO to B5.
5. B5 CHECK THE COOLING FAN OPERATION Key in OFF position. Carry out the cooling fan component tests. Refer to «FAN CLUTCH TEST»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__fan-clutch-test) . For 6.0L diesel, see «INTRODUCTION -- 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/testing-diagnostics/#engine-controls-introduction-60l-diesel) article. Is the cooling fan operation OK? Yes : GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-system-general-information) or Diagnosis and Testing of the engine. No : INSTALL a new fan component determined to be faulty. TEST the system for normal operation.

PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

1. C1 CHECK THE ENGINE TEMPERATURE Start the engine and allow the engine to idle for ten minutes. Key in OFF position. Feel the inlet and heater hoses and the underside of the upper radiator hose. Are the upper radiator hose and the heater hoses cold? Yes : INSTALL a new thermostat. TEST the system for normal operation. No : GO to «INSTRUMENT CLUSTER»(ref-231355) for diagnosis and testing of the engine coolant temperature gauge.

Pressure Test

1. Turn the engine OFF.
2. Check the engine coolant level. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Connect Radiator Heater Core Pressure Tester to the degas bottle nipple and overflow hose. Install a pressure test pump to the quick-connect fitting of the test adapter.
4. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained.
5. If the pressure relief cap does not hold pressure, remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the filler neck.
6. If 89 kPa (13 psi) cannot be reached, install a new pressure relief cap. If more than 124 kPa (18 psi) shows on gauge, install a new pressure relief cap.
7. Pressurize the engine cooling system as described in Step 4 (using a pressure relief cap that operates within the specified upper and lower pressure limits). Observe the gauge reading for approximately two minutes; refer to «GENERAL SPECIFICATIONS»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__general-specifications) . Pressure should not drop during this time.
8. Release the system pressure by loosening the pressure relief cap. Check the engine coolant level and replenish, if necessary, with the correct engine coolant mixture; refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

Thermostat

A new thermostat should be installed only after the following electrical and mechanical tests have been carried out.

Thermostat, Electrical Test-4.6L, 5.4L and 6.8L

Note. The electrical thermostat test is most accurate if carried out indoors at less than 37.8°C (100°F) ambient air. This test may be carried out with the hood open or closed and with the engine warm or cold.

1. Check the engine coolant level. Fill as needed.
2. With the ignition OFF, voltage values (0-5 V) may now be monitored while the cylinder head temperature (CHT) sensor retains its connection to the wiring harness. A scan tool is used to monitor the CHT voltage.
3. Place the automatic transmission in PARK (P) or the manual transmission in NEUTRAL (N) and engage the parking brake.
4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for two minutes, then record the CHT voltage. Record the CHT voltage every 60 seconds. When the CHT voltage trend changes direction or only changes slightly (0.03 volt or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart listed below. VOLTAGE AND COOLANT TEMPERATURE CHART Coolant Temperature °C (°F) CHT (Volts) 22 (71) 3.00 43 (109) 2.01 71 (159) 1.01 82 (180) 0.75 92 (197) 0.58 97 (206) 0.50 105 (221) 0.40
5. If the coolant thermostat opening voltage is greater than 0.58 volt and less than 92°C (197°F), install a new coolant thermostat.
6. If the coolant thermostat opening voltage is less than 0.58 volt and greater than 92°C (197°F), the coolant thermostat is good and a new coolant thermostat should not be installed. GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__symptom-chart) for further instructions.

Thermostat - Mechanical Test

1. Remove the thermostat.
2. Check the thermostat for seating. Hold the thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that a new thermostat should be installed. Some thermostats have a small leakage notch at one location on the perimeter of the thermostat valve, which is considered normal.
3. Immerse the thermostat in a boiling antifreeze and water mixture.
4. See the «GENERAL SPECIFICATIONS CHART»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling__general-specifications) for thermostat opening temperatures.

Radiator Leak Test, Removed From the Vehicle

Note. Always install plugs in the oil cooler fittings before leak-testing or cleaning any radiator.

Note. Clean the radiator before leak-testing to avoid contamination of tank.

1. Leak-test the radiator in clean water with 138 kPa (20 psi) air pressure.
2. If a stream of air bubbles is observed coming from the radiator, note the location and install a new radiator.

Fan Clutch Test

Note. The following test does not apply to the 6.0L diesel. For the 6.0L diesel, see INTRODUCTION -- 6.0L DIESEL article.

1. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked as follows

Fan Clutch Test - Minimum Speed Requirement

1. Use a suitable marker to mark the water pump pulley, one of the fan blade retaining bolts and the crankshaft pulley.
2. Connect a tachometer to the engine.
3. Install a throttle adjusting tool.
4. Connect the Digital Photoelectric Tachometer.
5. Start the engine and run it at approximately 1,500 rpm until the normal operating temperature has been achieved.
6. Adjust the engine speed to 2,300 rpm.
7. Operate the strobe light at 3,000 rpm and aim it at the coolant pump pulley. Adjust the engine speed until the light flash and the coolant pump pulley mark are synchronized.
8. Aim the strobe light at the fan blade bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade bolt (the fan blade appears to stand still).
9. The fan blade speed must not be greater than 1,500 rpm at 3,000 coolant pump rpm.
10. Turn the engine off.
11. If the fan blade speed was greater than 1,500 rpm, install a new fan clutch.

Fan Clutch Test - Maximum Speed Requirement

1. Carry out Steps 1 through 5 of the Fan Clutch Test - Minimum Speed Requirement.
2. Block off areas on each side of the radiator in the engine compartment and the front of the radiator grille. This will raise the temperature of the air striking the fan clutch and should cause the fan blade to operate at maximum speed.
3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position.
4. Adjust the strobe to 3,000 rpm.
5. Start the engine and adjust the engine speed until the strobe light flash and the water pump pulley mark are synchronized.
6. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade bolt (the fan blade appears to stand still).
7. If the fan blade speed is less than 2,300 rpm, install a new fan clutch.

SPECIAL TOOL RADKITPLUS 078-00497

Scheme 5

Material

MATERIAL SPECIFICATION

Draining

Note. Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.

1. Release the pressure in the cooling system. Make sure the engine is cool. Wrap a thick cloth around the coolant pressure relief cap on the degas bottle. Slowly turn the cap counterclockwise (left) until the pressure begins to release. Step back while the pressure releases When you are sure all the pressure has been released, use the cloth to turn and remove the cap.
2. Place a suitable container below the radiator draincock.
3. Open the radiator draincock and drain the coolant into a suitable container.
4. Close the radiator draincock when finished.

Filling and Bleeding with RADKITPLUS

1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer's instructions to fill and bleed the cooling system.

Filling without RADKITPLUS

1. Add the correct engine coolant mixture to the degas bottle.
2. Move the temperature blend selector to the full warm position.
3. Run the engine until it reaches operating temperature.
4. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the "COOLANT FILL LEVEL" marks.
5. Turn off the engine and allow the cooling system to cool.
6. Repeat Steps 1 through 5 until the degas bottle level is OK.

Bleeding without RADKITPLUS

1. Select the maximum heater temperature and medium low blower motor speed settings. Position the control to discharge air at the panel vents in the instrument panel.
2. Start the engine and allow to idle. While the engine is idling, feel for hot air at the panel vents.
3. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from the panel vents. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch.
4. Shut the engine off and allow to cool.
5. Check the engine for coolant leaks.
6. Check the engine coolant level in degas bottle and fill as necessary.

SPECIAL TOOLS Flush Kit Hardware Package 164-R3658 or equivalent Drain Kit 164-R3662 or equivalent Proflush and Fill Coolant Flush and Fill 023-00154 or equivalent

Scheme 6

Scheme 7

Flushing

1. Once pressure is released, remove the pressure relief cap. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the thermostat.
3. Install the coolant hose connection without the thermostat.
4. Use Premium Cooling System Flush VC-1 or equivalent meeting Ford specification ESR-M14P7A.
5. Install the thermostat.
6. Backflush the heater core. For additional information, refer to «HEATER CORE BACKFLUSHING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
7. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

SPECIAL TOOLS Flush Kit Hardware Package 164-R3658 or equivalent Drain Kit 164-R3662 or equivalent

Backflushing

1. Once pressure is released, remove the pressure relief cap.
2. Partially drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Use an appropriate cooling system flusher to backflush the heater core. Use Premium Cooling System Flush VC-1 or equivalent meeting Ford specification ESR-M14P7-A.
4. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

Scheme 8

Scheme 9

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Remove the engine cover. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
4. Disconnect the block heater electrical connector.
5. Remove the block heater. Remove and discard the O-ring seal.
6. To install, reverse the removal procedure. Install a new O-ring seal.

Scheme 10

Scheme 11

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Disconnect the coolant hoses at the degas bottle.
3. Remove the bolts and position out the degas bottle.
4. Disconnect the engine fill tube and remove the degas bottle.
5. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

Scheme 12

Scheme 13

Scheme 14

1. Remove the fan and fan clutch. For additional information, refer to «COOLING FAN - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
3. Remove the coolant pump pulley. Remove the bolts. Remove the coolant pump pulley.
4. Remove the bolts.
5. Remove the coolant pump from the cylinder block.

Scheme 15

Scheme 16

1. Install a new O-ring on the coolant pump. Coat the new O-ring with engine coolant.
2. Install the coolant pump. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. Position the coolant pump into the engine block. Install the bolts.
3. Position the pulley onto the coolant pump and install the bolts.
4. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(/ford/cutaway-e350/2004-2007/remont/accessory-drive-belts/#accessory-drive-system) .
5. Install the fan and fan clutch. For additional information, refer to «RADIATOR - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

Scheme 17

Scheme 18

Scheme 19

1. Remove the cooling fan stator. For additional information, refer to «COOLING FAN STATOR - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the accessory drive belt.
3. Remove the bolts and the coolant pump pulley.
4. Remove the bolts and the coolant pump. Remove and discard the O-ring seal.
5. To install, reverse the removal procedure. Clean and inspect the coolant pump mounting.

Scheme 20

Scheme 21

Scheme 22

Scheme 23

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the cooling fan. For additional information, refer to «COOLING FAN - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. If equipped, remove the underbody splash shield.
4. Disconnect the transmission oil cooler hoses. Plug or cap the lines as needed.
5. Disconnect the lower radiator hose.
6. Remove the four bolts and the radiator support brackets.
7. Remove the radiator from the vehicle.
8. To install, reverse the removal procedure. If necessary, install new appropriately sized worm drive-type clamps.

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Remove the pushpin retainers and upper air deflector.
4. Remove the bolts for the power steering reservoir bracket.
5. Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.
6. Disconnect the coolant hoses from the air cleaner outlet tube.
7. Loosen the clamps and remove the air cleaner outlet tube.
8. Loosen the clamps and remove the charge air cooler pipe.
9. Loosen the clamps and remove the charge air cooler hose.
10. Disconnect the radiator vent hose.
11. Disconnect and remove the upper radiator hose.
12. Remove the pushpin retainers and lower air deflector.
13. Disconnect the transmission cooler hoses. Plug or cap the lines as needed.
14. Disconnect the lower radiator hose.
15. Remove the two bolts and the lower shroud.
16. Disconnect the transmission cooler hoses and remove the lower shroud.
17. Remove the bolts and the radiator mounting brackets.
18. Remove the two bolts and position the A/C condenser forward.
19. Disconnect the oil level indicator and tube.
20. Remove the cooling module from the vehicle.
21. To install, reverse the removal procedure.

SPECIAL TOOLS Holding Wrench, Fan Clutch Pulley (4.6L, 5.4L) 303-239 (T84T-6312-C) Wrench, Fan Clutch Hub Nut (4.6L, 5.4L) 303-240 (T84T-6312-D) Holding Wrench, Fan Clutch Pulley (6.8L) 303-478 (94T-6312-AH) Wrench, Fan Clutch Hub Nut (6.8L) 303-214 (T83T-6312-B)

Scheme 36

Scheme 37

Scheme 38

All vehicles

Note. The fan, fan clutch and shroud must be removed and installed together due to insufficient clearance to remove them separately.

Scheme 39

Scheme 40

Scheme 41

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
3. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
4. Disconnect the radiator upper hose and the overflow hose from the radiator. Position the hoses aside.
5. Disconnect the coolant degas bottle and power steering hose from the shroud.
6. Using the special tools, loosen the fan clutch.
7. Using the special tools, loosen the fan clutch.
8. Carefully rotate the fan and fan clutch assembly counterclockwise until the assembly is free from the coolant pump. Place the fan and fan clutch into the shroud opening.
9. Disconnect the lower radiator hose retaining clamp from the shroud.
10. If equipped, disconnect the underbody splash shield from the shroud.
11. Remove the mounting bolts and the fan, fan clutch and shroud.
12. To install, reverse the removal procedure. If necessary, install new appropriately sized worm drive-type clamps.
13. Fill and bleed the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .

SPECIAL TOOL Wrench, Fan Clutch Nut 303-591

Scheme 42

Scheme 43

1. Remove the radiator. For additional information, refer to «RADIATOR - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Disconnect the electrical connector. Release the wiring from the stator.
3. Using the special tool, loosen the fan clutch by turning the wrench counterclockwise. Remove the cooling fan and clutch.
4. Remove the bolts and cooling fan stator assembly.
5. To install, reverse the removal procedure.

Scheme 44

Scheme 45

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the air cleaner and air cleaner outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350/2004-2007/remont/removal-installation/#intake-air-distribution-filtering) .
3. Remove the bolts and the thermostat housing. Position the thermostat housing aside.
4. Remove the O-ring seal and thermostat. Clean and inspect the sealing surfaces.
5. To install, reverse the removal procedure.

Scheme 46

Scheme 47

Scheme 48

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the push pin retainers and upper air deflector.
3. Remove the bolts for the power steering reservoir bracket.
4. Remove the bolts and power steering fluid indicator. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position aside.
5. Disconnect the coolant hoses from the air cleaner outlet tube.
6. Loosen the clamps and remove the air cleaner outlet tube.
7. Loosen the clamps and remove the charge air pipe.
8. Disconnect and position the upper radiator hose aside.
9. Remove the retaining nut and position the fuel line retainer aside.
10. Remove the stud bolts and thermostat assembly. Remove and discard the O-ring seal.
11. To install, reverse the removal procedure. Install a new O-ring seal on the thermostat assembly.

Scheme 49

Scheme 50

Scheme 51

1. Remove the radiator. For additional information, refer to «RADIATOR - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
2. Remove the push pin and radiator air deflector.
3. Remove the bolts and fan shroud.
4. Remove the bolts and separate the charge air cooler from the radiator.
5. Remove the bolts and brackets from the radiator.
6. To assemble, reverse the disassembly procedure. Install the LH bolts first, for alignment of the charge air cooler to the radiator.

See also:
• ENGINE SYSTEM-GENERAL INFORMATION
• INTRODUCTION -- 6.0L DIESEL
• JACKING & LIFTING
• FRONT END BODY PANELS
• ACCESSORY DRIVE
• INTAKE AIR DISTRIBUTION & FILTERING
• COMPONENT TESTS
• SYMPTOM CHART
• PINPOINT TEST A
• PINPOINT TEST B
• PINPOINT TEST C
• PRESSURE TEST
• FAN CLUTCH TEST
• GENERAL SPECIFICATIONS