Engine Cooling System: Removal & Installation Ford Explorer IV

REMOVAL AND INSTALLATION

1. Drain the engine cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
2. Release the clamp and disconnect the upper radiator hose from the thermostat housing cover.
3. Remove the bolts and the thermostat housing cover. To install, tighten to 10 N.m (89 lb-in).
4. Remove the thermostat.
5. To install, reverse the removal procedure.

1. Drain the engine cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
2. Disconnect the engine coolant temperature (ECT) sensor electrical connector.
3. Release the clamp and disconnect the upper radiator hose.
4. Release the clamp and disconnect the heater hose.
5. Release the bypass hose clamp and position it down the hose.
6. Remove the bolts and the thermostat housing. To install, tighten to 12 N.m (9 lb-ft).
7. Inspect the thermostat housing O-ring seal. Install a new O-ring seal if necessary.
8. To install, reverse the removal procedure.

Scheme 9

1. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
2. Remove the throttle body. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.6L (3V)»(ref-270905) .
3. Disconnect the fuel vapor tube.
4. Remove the bolts and position the thermostat housing cover aside.
5. Remove the O-ring seal and the thermostat.

INSTALLATION

1. Install the thermostat with the spring facing down.
2. Install the O-ring seal.
3. Position the thermostat housing cover and the bolts. Tighten to 10 Nm (89 lb-in).
4. Connect the fuel vapor hose.
5. Install the throttle body. For additional information, refer to «FUEL CHARGING AND CONTROLS - 4.6L (3V)»(ref-270905) .
6. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .

1. Drain the engine cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
2. Remove the cooling fan. For additional information, refer to «Cooling Fan»(ref-270902-S21592733712007110700000) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-270912) .
4. Remove the bolts and the coolant pump pulley. To install, tighten to 25 N.m (18 lb-ft).
5. Release the clamp and disconnect the coolant pump bypass hose.
6. Release the clamp and disconnect the heater hose.
7. Release the clamp and disconnect the lower radiator hose.
8. Remove the bolts, the coolant pump and the gasket. To install, tighten to 10 N.m (89 lb-in).
9. Clean the mating surfaces with a plastic scraper and metal surface prep. Follow the directions on the packaging.
10. To install, reverse the removal procedure. Install a new coolant pump gasket.

1. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
2. Remove the cooling fan. For additional information, refer to «Cooling Fan»(ref-270902-S21592733712007110700000) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-270912) .
4. Remove the bolts and the coolant pump pulley. To install, tighten to 25 N.m (18 lb-ft).
5. Remove the bolts and the coolant pump. To install, tighten to 25 N.m (18 lb-ft).
6. Remove and discard the coolant pump O-ring.
7. Clean the mating surfaces with a plastic scraper, if necessary, and metal surface prep. Follow the directions on the packaging.
8. To install, reverse the removal procedure. Install a new coolant pump O-ring. Lubricate the O-ring with clean engine coolant.

Scheme 10

Scheme 11

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-270948) .
2. Drain the engine cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
3. Remove the intake manifold. For additional information, refer to «ENGINE - 4.6L (3V)»(ref-270890) .
4. Rotate the accessory drive belt tensioner clockwise and detach the belt from the generator pulley.
5. Disconnect the electrical connector.
6. Loosen the generator nuts. To install, tighten to 25 Nm (18 lb-ft).
7. Remove the generator bracket-to-coolant crossover bolts, and position the generator, bracket and wiring harness aside as an assembly. To install, tighten to 10 Nm (89 lb-in).
8. Disconnect the PCV heater hose from the coolant crossover manifold assembly.
9. Disconnect the heater hose from the coolant crossover manifold assembly.
10. Disconnect the upper radiator hose from the coolant crossover manifold assembly.
11. Remove the bolts, the coolant crossover manifold assembly and the gaskets. Discard the gaskets. To install, tighten to 10 Nm (89 lb-in).
12. To install, reverse the removal procedure. Install new gaskets.

Scheme 12

Scheme 13

Scheme 14

Scheme 15

Scheme 16

1. For additional information, refer to the appropriate procedures.

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-270881) .
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-270902-S23782127182007110700000) .
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
4. Remove the coolant expansion tank. For additional information, refer to «Coolant Expansion Tank»(ref-270902-S33808349442007110700000) .
5. Remove the bolt and position the power steering fluid reservoir aside. To install, tighten to 10 Nm (89 lb-in).
6. Release the clamp and disconnect the upper radiator hose.
7. Release the clamp and disconnect the lower radiator hose.
8. Detach the lower radiator hose retainer from the lower fan shroud.
9. Detach the transmission cooler hose retainer from the RH radiator support bracket.
10. Remove the 4 lower radiator air deflector pushpins.
11. Remove the latch assemblies from the transmission cooler tubes.
12. Using the special tool, disconnect the transmission cooler tubes.
13. Remove the upper fan shroud bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. To install, tighten to 7 Nm (62 lb-in).
14. Disconnect the fan clutch electrical connector.
15. Remove the fan clutch wiring harness bracket bolt. To install, tighten to 7 Nm (62 lb-in).
16. Using the special tools, remove the cooling fan. To install, tighten to 55 Nm (41 lb-ft).
17. Remove the bolts and the lower fan shroud.
18. Detach the A/C tube from the retainer on the radiator support bracket.
19. Remove the radiator support bracket-to-radiator support bracket bolts. To install, tighten to 15 Nm (11 lb-ft).
20. Remove the radiator top seal.
21. Deflect the A/C condenser seals and remove the A/C condenser-to-radiator support bracket bolts. Position the A/C condenser aside. To install, tighten to 12 Nm (9 lb-ft).
22. Remove the radiator and the radiator support brackets as an assembly.
23. Remove the bolts and separate the radiator support brackets and the radiator. To install, tighten to 12 Nm (9 lb-ft).
24. To install, reverse the removal procedure.

Vehicle equipped with a 4.6L (3V)

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
2. Remove the coolant expansion tank. For additional information, refer to «Coolant Expansion Tank»(ref-270902-S33808349442007110700000) .
3. Remove the bolt and position the power steering fluid reservoir aside. To install, tighten to 10 Nm (89 lb-in).
4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. To install, tighten to 7 Nm (62 lb-in).
5. Disconnect the fan clutch electrical connector.
6. Remove the fan clutch wiring harness bracket bolt. To install, tighten to 7 Nm (62 lb-in).
7. Using the special tools, remove the cooling fan. To install, tighten to 55 Nm (41 lb-ft).
8. Remove the bolts and separate the fan from the fan clutch. To install, tighten to 7 Nm (62 lb-in).
9. If necessary, unclip and disconnect the fan clutch wiring harness.
10. To install, reverse the removal procedure.

Vehicles equipped with a 4.6L (3V) engine

1. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING»(ref-270901) .
2. Remove the coolant expansion tank. For additional information, refer to «Coolant Expansion Tank»(ref-270902-S33808349442007110700000) .
3. Remove the bolt and position the power steering fluid reservoir aside. To install, tighten to 10 Nm (89 lb-in).
4. Remove the bolts, then unclip the upper fan shroud from the lower fan shroud and remove the upper fan shroud. To install, tighten to 7 Nm (62 lb-in).
5. Disconnect the fan clutch electrical connector.
6. Remove the fan clutch wiring harness bracket bolt. To install, tighten to 7 Nm (62 lb-in).
7. Using the special tools, remove the cooling fan. To install, tighten to 55 Nm (41 lb-ft).
8. Remove the bolts and the lower fan shroud. To install, tighten to 7 Nm (62 lb-in).
9. To install, reverse the removal procedure.