Engine Cooling System: Removal & Installation Ford Explorer V

Removal

Note. Removal steps in this procedure may contain installation details.

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1. REFER to «Cooling System Draining, Filling and Bleeding - 2.0L GTDI»(ref-517561-S31925988682012121200000) .
2. NOTE: To install, route the block heater power cable away from hot or rotating components, or the cable can be damaged.
3. 40 Nm (30 lb-ft).

Installation

1. To install, reverse the removal procedure.
2. REFER to «Cooling System Draining, Filling and Bleeding - 2.0L GTDI»(ref-517561-S31925988682012121200000) .

1. Drain the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .
2. Detach the block heater electrical connector heat shield.
3. Disconnect the block heater electrical connector.
4. Remove the block heater.

1. Install the block heater. Tighten to 40 Nm (30 lb-ft).
2. NOTE: Make sure that the block heater wiring is routed and secured away from rotating or hot components, or the wiring may be damaged. Connect the block heater electrical connector.
3. Attach the block heater electrical connector heat shield.
4. Fill and bleed the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .

1. Remove the lower intake manifold. REFER to «LOWER INTAKE MANIFOLD - 3.5L»(ref-517529-S36284724522012121200000) .
2. Disconnect the degas bottle-to-coolant pipe hose.
3. Detach the thermostat housing from the coolant inlet pipe and remove the coolant inlet pipe. Remove and discard the O-ring seals.

1. NOTE: Use Motorcraft® Specialty Green Engine Coolant or. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system. NOTE: Motorcraft® Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade. Lubricate the coolant outlet pipe O-ring seals with clean engine coolant and install the O-ring seals on the coolant outlet pipe.
2. Install the coolant outlet pipe and attach the thermostat housing.
3. Install the lower intake manifold. REFER to «LOWER INTAKE MANIFOLD - 3.5L»(ref-517529-S36284724522012121200000) .

Radiator - 2.0L GTDI

Note. Removal steps in this procedure may contain installation details.

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1. REFER to «Cooling System Draining, Filling and Bleeding - 2.0L GTDI»(ref-517561-S31925988682012121200000) .
2. REFER to «Cooling Fan Motor and Shroud - 2.0L GTDI»(ref-517561-S37419860512012121200000) .
3. REFER to «BUMPER COVER - FRONT»(ref-517604-S34304040952012121200000) .
4. 5 Nm (44 lb-in).
5. Position the top of the radiator toward the engine for access. 5 Nm (44 lb-in).
6. Position the top of the radiator toward the engine for access.
7. NOTE: The longer bolt is installed on the LH side. Position the top of the radiator toward the engine for access. 8 Nm (71 lb-in). 6 Nm (53 lb-in).
8. Position the top of the radiator toward the engine for access. 6 Nm (53 lb-in).

1. To install, reverse the removal procedure.
2. REFER to «Cooling System Draining, Filling and Bleeding - 2.0L GTDI»(ref-517561-S31925988682012121200000) .

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1. Drain the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .
2. Remove the cooling fan motor and shroud. REFER to «Cooling Fan Motor and Shroud - 3.5L Ti-VCT»(ref-517561-S32293205212012121200000) .
3. Remove the front bumper cover. REFER to «BUMPER COVER - FRONT»(ref-517604-S34304040952012121200000) .
4. Release the clamp and disconnect the upper radiator hose from the radiator.
5. Release the clamp and disconnect the lower radiator hose from the radiator.
6. Remove the 2 upper support bracket bolts and position the radiator toward the engine.
7. Remove the 2 upper radiator brackets.
8. Remove the LH and RH air deflectors from the A/C condenser.
9. Remove the 2 A/C condenser bolts and separate the condenser from the radiator.
10. Pry the clip up off the radiator and remove the upper radiator air deflector.
11. Remove the radiator.

1. Position the radiator in the vehicle, making sure the lower air deflector is under the A/C condenser.
2. NOTE: The longer bolt goes on the LH side. Attach the A/C condenser to the radiator and install the 2 bolts. Tighten to 6 Nm (53 lb-in).
3. Install the upper radiator air deflector and attach the clip to the radiator.
4. Install the LH and RH air deflectors on the A/C condenser.
5. Install the 2 upper radiator brackets.
6. Position the radiator and install the 2 upper radiator bracket bolts. Tighten to 5 Nm (44 lb-in).
7. Connect the lower radiator hose to the radiator and position the clamp.
8. Connect the upper radiator hose to the radiator and position the clamp.
9. Install the front bumper cover. REFER to «BUMPER COVER - FRONT»(ref-517604-S34304040952012121200000) .
10. Install the cooling fan motor and shroud. REFER to «Cooling Fan Motor and Shroud - 3.5L Ti-VCT»(ref-517561-S32293205212012121200000) .
11. Fill and bleed the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .

Note. Removal steps in this procedure may contain installation details.

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1. Remove the ACL housing. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
2. If equipped.
3. 5 Nm (44 lb-in).
4. 6 Nm (53 lb-in).

1. To install, reverse the removal procedure.

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1. Remove the ACL. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
2. If equipped, detach the block heater wiring harness from the engine wiring harness.
3. Disconnect the cooling fan electrical connector.
4. Detach the 8 wiring harness retainers.
5. Detach the hood latch cable from the clip on the cooling fan motor and shroud.
6. Detach the upper radiator hose from the upper radiator hose support.
7. Release the tab through the access hole and remove the upper radiator hose support.
8. Remove the 2 bolts and the cooling fan motor and shroud.

1. Position the cooling fan motor and shroud and install the 2 bolts. Tighten to 6 Nm (53 lb-in).
2. Install the upper radiator hose support.
3. Attach the upper radiator hose to the support.
4. Attach the hood release cable to the clip on the cooling fan motor and shroud.
5. Attach the 8 wiring harness retainers.
6. Connect the cooling fan electrical connector.
7. If equipped, attach the block heater wiring harness to the engine wiring harness.
8. Install the ACL. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .

1. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Allow the engine to cool and remove the pressure relief cap.
2. Using hose pinch pliers, clamp the lower radiator hose at the degas bottle (2.0L GTDI) or the degas bottle-to-coolant inlet tube hose (3.5L Ti-VCT (+).
3. Siphon the coolant from the degas bottle.
4. Detach the A/C line pushpin from the degas bottle.
5. Release the clamp and disconnect the degas bottle-to-thermostat housing hose from the degas bottle.
6. Release the clamp and disconnect the lower radiator hose (2.0L GTDI) or the degas bottle-to-coolant inlet tube hose (3.5L Ti-VCT ) from the degas bottle.
7. Remove the 2 bolts and the degas bottle.

1. Position the degas bottle in the vehicle and install the bolts. Tighten to 9 Nm (80 lb-in).
2. Connect the lower radiator hose (2.0L GTDI) or the degas bottle-to-coolant inlet tube hose (3.5L Ti-VCT ) and position the clamp.
3. Connect the degas bottle-to-thermostat housing and position the clamp.
4. Attach the A/C line pushpin to the degas bottle.
5. Remove the hose pinch pliers.
6. NOTE: Use Motorcraft® Specialty Green Engine Coolant or. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system. NOTE: Motorcraft® Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade. Fill the degas bottle to the cold fill range with a 50/50 mixture of Motorcraft® Specialty Green Engine Coolant or and distilled water.

1. Drain the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .
2. Remove the ACL outlet pipe. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
3. Remove the 2 bolts and position the coolant inlet connection aside.
4. Remove the thermostat and the O-ring seal. Discard the O-ring seal.

1. NOTE: Use Motorcraft® Specialty Green Engine Coolant or. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system. NOTE: Motorcraft® Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade. Install a new O-ring seal and the thermostat. Lubricate the O-ring seal with clean engine coolant.
2. Position the coolant inlet connector and install the 2 bolts. 10 Nm (89 lb-in).
3. Install the ACL outlet pipe. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
4. Fill and bleed the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .

Note. Removal steps in this procedure may contain installation details.

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1. REFER to «Cooling System Draining, Filling and Bleeding - 2.0L GTDI»(ref-517561-S31925988682012121200000) .
2. 10 Nm (89 lb-in).

1. To install, reverse the removal procedure.
2. REFER to «Cooling System Draining, Filling and Bleeding - 2.0L GTDI»(ref-517561-S31925988682012121200000) .

1. Drain the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .
2. Remove the ACL outlet tube. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
3. Release the clamps, disconnect the 5 coolant hoses from the thermostat housing and position them aside.
4. Remove the 2 thermostat housing bolts.
5. NOTE: Do not pull the other end of the coolant tube out of the engine block when separating the thermostat housing. Separate the thermostat housing from the coolant tube and remove the thermostat housing. Remove and discard the thermostat housing-to-coolant tube O-ring seal and the thermostat housing gasket.

Note. Use Motorcraft® Specialty Green Engine Coolant or. Use the same type of coolant that was originally used to fill the cooling system. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.

Note. Motorcraft® Specialty Green Engine Coolant is very sensitive to light. Do NOT allow this product to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes this product to degrade.

1. Install a new thermostat housing-to-coolant inlet pipe O-ring seal and lubricate it with clean engine coolant.
2. Install a new thermostat housing gasket, the thermostat and the 2 bolts.
3. Tighten the 2 thermostat housing bolts in 2 stages. Stage 1: Tighten to 8 Nm (71 lb-in). Stage 2: Tighten an additional 90 degrees.
4. Connect the 5 coolant hoses to the thermostat housing and position the clamp.
5. Install the ACL outlet pipe. REFER to «INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW»(ref-517563-S09135048742012121200000) .
6. Fill and bleed the cooling system. REFER to «Cooling System Draining, Filling and Bleeding - 3.5L Ti-VCT»(ref-517561-S41303553832012121200000) .