Engine Cooling System Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

The cooling system components are

1. Engine coolant temperature (ECT) sensor
2. Radiator
3. Degas bottle
4. Radiator draincock
5. Coolant pump
6. Thermostat
7. Variable speed fan motor assembly
8. Fan control module (FCM)

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

The fan motor

1. operates only when the ignition switch is in the RUN position.
2. has variable speeds and is controlled by fan control module.

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.

Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.

When adding engine coolant, use a 50/50 mixture of clean distilled water and engine coolant.

To maintain the integrity of the coolant and the cooling system

1. Add Motorcraft Premium Gold Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent meeting Ford Specification WSS-M97B51-A1 (yellow color). Do not mix coolant types.
2. Do not add/mix orange-colored Motorcraft Specialty Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D or green colored Motorcraft Premium Engine Coolant VC-4-A (in Oregon and California VC-5) or equivalent (green color) meeting Ford specification ESE-M97B44-A. Mixing coolants may degrade the coolant's corrosion protection.
3. Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
4. Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available.

Refer to SYSTEM WIRING DIAGRAMS (Montego), SYSTEM WIRING DIAGRAMS (Five Hundred). or SYSTEM WIRING DIAGRAMS (Freestyle) for schematic and connector information.

Special Tool(s)

SPECIAL TOOL CHART Pressure Test Kit 014-R1072 or equivalent 73III Automotive Meter 105-R0057 or equivalent Battery/Antifreeze Tester 014-R1060 or equivalent Worldwide Diagnostic System (WDS) Vehicle Communication Module (VCM) with appropriate adapters, or equivalent diagnostic tool

Scheme 1

Scheme 2

Scheme 3

Material

MATERIAL CHART

Cooling Fans

The cooling fans are controlled by a fan control module. The fan control module receives a variable signal from the powertrain control module (PCM). If DTC P0480 is present, refer to the INTRODUCTION - GASOLINE article for diagnosis.

Inspection and Verification

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

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. VISUAL INSPECTION CHART Mechanical Electrical Leaks Restricted airflow coolant through the condenser/radiator Damaged hoses Loose/damaged hose clamps Damaged gasket Damaged head gaskets Damaged intake manifold gasket Damaged coolant pump Damaged radiator Damaged degas bottle Damaged heater core Damaged engine coolant temperature (ECT) sensor Damaged wiring Electric cooling fans Fuse Fan control module Circuitry
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, connect the diagnostic tool to the data link connector (DLC) and select the vehicle to be tested from the diagnostic tool menu. If the diagnostic tool does not communicate with the vehicle: check that the program card is correctly installed. check the connections to the vehicle. check the ignition switch position.
5. If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool operating manual.
6. Carry out the diagnostic tool data link test. If the diagnostic tool responds with: (appropriate communication networks, such as SCP, ISO, UBP, CAN) circuit fault; all electronic control units no response/not equipped, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#module-communications-network-system) . No response/not equipped for generic electronic module (GEM), refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/five-hundred/i-2004-2007/remont/communication-devices/#multifunction-electronic-modules-system) . System passed, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out the self-test diagnostics for the GEM.
7. If the DTCs retrieved are related to the concern, go to the «GENERIC ELECTRONIC MODULE (GEM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__powertrain-control-module-diagnostic-trouble-code) .
8. If no DTCs related to the concern are retrieved, GO to the «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__symptom-chart) .

Powertrain Control Module Diagnostic Trouble Code (DTC) Index

POWERTRAIN CONTROL MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX

Symptom Chart

SYMPTOM CHART

Possible causes

1. Radiator
2. Thermostat housing assembly
3. Throttle body adapter heating
4. Coolant pump seal
5. Radiator hoses
6. Heater hoses
7. Heater core
8. Engine gaskets
9. Degas bottle

Testing

1. A1 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: 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 INSPECT THE DEGAS BOTTLE PRESSURE RELIEF CAP 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). Remove the pressure relief cap. Inspect the pressure relief cap for foreign material between the sealing gasket and the diaphragm. Test the pressure relief cap. Refer to «COMPONENT TESTS»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) . Is the pressure relief cap OK? Yes : Go to A3. No : CLEAN or INSTALL a new pressure relief cap. TEST the system for normal operation.
3. A3 CHECK THE ENGINE COOLANT FOR INTERNAL LEAK 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). Inspect the engine coolant in the degas bottle for signs of engine oil. Is oil evident in the coolant? Yes : If engine oil is evident, REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine-system-general-information) . No : GO to A4.
4. A4 CHECK THE ENGINE FOR COOLANT Remove the oil level indicator from the engine. Is coolant evident in the oil? Yes : If coolant is in the engine, REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine-system-general-information) . No : GO to A5.
5. A5 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to the «COMPONENT TESTS»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) . 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/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__symptom-chart) .

1. Low coolant level
2. Thermostat
3. Airlock in the system
4. Coolant pump
5. Internal engine coolant leak
6. Radiator
7. Radiator airflow obstruction
8. Cooling fan
9. Pressure relief cap

1. B1 CHECK THE ENGINE COOLANT LEVEL NOTE: If the engine is hot, allow the engine to cool before proceeding. Key in OFF position. 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). 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/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. B2 CHECK THE COOLANT CONDITION Check the coolant for dirt, rust or contamination. Is the coolant condition OK? Yes : GO to B3. No : FLUSH the engine cooling system. REFER to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) . 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 B4.
4. B4 CHECK THE THERMOSTAT OPERATION Key in START position. Start the engine and allow the engine to run for 10 minutes. Key in OFF position. Feel the upper and lower radiator hose. Are the upper and lower radiator hoses cold? Yes : CARRY OUT the «Thermostat»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__thermostat) component tests. No : GO to B5.
5. B5 CHECK THE COOLING FAN OPERATION Using the diagnostic tool, cycle the cooling fans to the HIGH and LOW positions. Do the cooling fans operate? Yes : REFER to «ENGINE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/mechanical/#engine-system-general-information) for diagnosis and testing of the engine. No : REFER to the «INTRODUCTION - GASOLINE»(/ford/five-hundred/i-2004-2007/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article to diagnose cooling fans.

1. Thermostat

1. C1 CHECK THE ENGINE TEMPERATURE Key in START position. Start the engine and allow the engine to idle for 10 minutes. Key in OFF position. Feel the upper and lower radiator hoses. Are the upper and lower radiator hoses cold? Yes : CARRY OUT the «Thermostat»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__thermostat) component tests. No : REFER to «INSTRUMENT CLUSTER»(/ford/five-hundred/i-2004-2007/remont/gauges-instrument-panels/#instrument-cluster-system) 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/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Connect the 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. Pressure check the pressure relief cap. If 89 kPa (13 psi) cannot be reached or if more than 124 kPa (18 psi) show on the 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 2 minutes; refer to «GENERAL SPECIFICATIONS»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__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/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

Cap

1. Make sure the engine is cool.
2. Wrap a thick cloth around the coolant pressure relief cap on the coolant reservoir. Slowly turn the cap counterclockwise (left) until the pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure all the pressure has been released, use the cloth to turn and remove the cap.
5. Immerse the pressure relief cap in water and install it on the shallow filler neck of Radiator/Heater Core Pressure Tester and Radiator Cap Adapter, part of Radiator/Heater Core Pressure Tester.
6. Immerse the filler neck seal in water and install it in the filler neck adapter.
7. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter.
8. Connect the female quick-connect fitting of the pressure test pump to the male quick-connect fitting of the filler neck adapter.
9. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained.
10. Release the pressure by turning the relief screw counterclockwise. Then tighten the pressure relief screw and repeat Step 6 (at least twice) to make sure the reading is repeatable within the specifications of the pressure relief cap.
11. If the pressure test gauge readings are not within specifications, install a new pressure relief cap. If the pressure test gauge readings are within specifications, carry out the «Pressure Test»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__pressure-test) .

Thermostat

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

Thermostat - Electrical Test

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 or without the hood open and with the engine warm or cold.

1. Check the engine coolant level. Fill as needed.
2. With the ignition OFF, attach the 73III Automotive Meter to the engine coolant temperature (ECT) Sensor. Voltage values (0-5 V) may now be monitored while the sensor retains its connection to the wiring harness. A diagnostic tool or the Service Bay Diagnostic System (SBDS) may be used to monitor the ECT. The SBDS sequence to use for the screen is: Toolbox-Electronic Engine Control and DCL-Item.
3. Place the transmission in PARK (P) or NEUTRAL (N).
4. Start the engine and allow the engine to idle throughout this test. Allow the engine to run for 2 minutes, then record the ECT voltage. Record the ECT voltage every 60 seconds. When the ECT 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. DIAGNOSIS PROCEDURE Coolant Temperature °C (°F) ECT (Volts) 20 (68) 3.14 45 (113) 2.98 70 (158) 1.08 75 (167) 0.94 82 (180) 0.75 90 (194) 0.64 95 (202) 0.53 100 (212) 0.49 105 (221) 0.43
5. If the thermostat opening voltage is greater than 0.94 volt and less than 75°C (167°F), or less than 0.53 and greater than 95°C (202°F), install a new thermostat.
6. If the thermostat opening voltage is less than 0.75 volt and greater than 82°C (180°F) or greater than 0.50 volt and less than 97°C (206°F), the thermostat is good and a new thermostat should not be installed. GO to «SYMPTOM CHART»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__symptom-chart) for further instructions.

Thermostat - Mechanical Test

1. Remove the thermostat housing.
2. Immerse the thermostat housing and thermostat in a boiling antifreeze and water mixture.
3. See the «GENERAL SPECIFICATIONS CHART»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__general-specifications) for thermostat opening temperatures.

Radiator Leak Test, Removed From the Vehicle

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.

SPECIAL TOOL CHART RADKITPLUS 078-00497

Scheme 4

MATERIAL CHART

Draining

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

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

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap.
3. Remove the front splash shield.
4. Place a suitable container below the radiator draincock. Drain the coolant.
5. Close the radiator draincock and install the front splash shield when finished.

Filling and Bleeding with RADKITPLUS

Note. For vehicles equipped with an optional rear heater, RADKITPLUS must be used whenever the underbody coolant lines and/or rear heater core are drained or removed.

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

Filling and Bleeding without RADKITPLUS

Note. For vehicles equipped with an optional rear heater, RADKITPLUS must be used whenever the underbody coolant lines and/or rear heater core are drained or removed.

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

1. Fill the degas bottle with the correct engine coolant mixture to the degas bottle seam line.
2. Install the pressure relief cap.
3. Remove the retaining clip and the fill tab on the top of the thermostat housing and fill through the thermostat housing until full.
4. Install the fill tab and retaining clip.
5. Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air from the A/C vents in the instrument panel.
6. Start the engine and allow it to idle until engine reaches normal operating temperature. While the engine is idling, feel for hot air from the A/C vents.
7. Run the engine at 3,000 rpm for 10 minutes. Hot air should discharge from the A/C 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. Shut the engine off and allow it to cool. Check the engine for coolant leaks. Check the engine coolant level in the degas bottle and fill to the seam line.

MATERIAL CHART

1. To remove rust, sludge and other foreign material from the cooling system, use cooling system flush that is safe for use with aluminum radiators. For additional information, refer to «SPECIFICATIONS»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) . This cleaning restores cooling system efficiency and helps prevent overheating. A pulsating or reversed direction of flushing water will loosen sediment more quickly than a steady flow in the normal coolant flow direction. In severe cases where cleaning solvents will not clean the cooling system efficiently, it will be necessary to use the pressure flushing method using cooling system flusher. Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the radiator. For additional information, refer to «RADIATOR»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Backflush the radiator with the radiator in an upside-down position with a high-pressure hose in the lower hose location and backflush.
5. Remove the thermostat. For additional information, refer to «THERMOSTAT»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system__thermostat) .
6. Backflush the engine. Position the high-pressure water hose into the engine through the engine return and backflush the engine.
7. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 5

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Disconnect the block heater electrical connector and position aside.
5. Remove the block heater. To install, tighten to 21 Nm (15 lb-ft).
6. To install, reverse the removal procedure.
7. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 6

Scheme 7

1. For additional information, refer to the «PROCEDURES»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

MATERIAL CHART

Removal

1. Remove the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) and «THERMOSTAT AND THERMOSTAT HOUSING - EXPLODED VIEW»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the 3 thermostat housing bolts and separate the upper and lower thermostat housing.
3. Remove the thermostat. Remove the O-ring seal and discard. Remove the thermostat.

Installation

1. Align the thermostat bridge with the alignment marks and install it in the upper housing.
2. Lubricate a new O-ring seal with clean engine coolant and install it in the upper housing.
3. Install the lower thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
4. Install the thermostat housing. For additional information, refer to «THERMOSTAT AND THERMOSTAT HOUSING - EXPLODED VIEW»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) and «THERMOSTAT HOUSING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
5. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

MATERIAL CHART

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Disconnect the degas bottle-to-thermostat housing hose and position aside.
4. Disconnect the throttle body-to-thermostat housing hose and position aside.
5. Disconnect the upper radiator-to-thermostat housing hose and position aside.
6. Disconnect the bypass tube-to-thermostat housing hose and position aside.
7. Disconnect the heater hose from the thermostat housing and position aside.
8. Disconnect the lower radiator-to-thermostat housing hose and position aside.
9. Remove the 2 bolts and the thermostat housing. Discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
10. To install, reverse the removal procedure. Install a new O-ring on the thermostat housing and lubricate with clean engine coolant.
11. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 8

Scheme 9

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Disconnect the thermostat housing-to-bypass tube hose and position aside.
4. Remove the 2 thermostat housing bolts and position aside the thermostat housing. Discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
5. Remove the 4 roll restrictor bracket bolts and the roll restrictor bracket. To install, tighten to 55 Nm (40 lb-ft).
6. Disconnect the bypass tube hose and position aside.
7. Disconnect the bypass tube electrical connector.
8. Remove the 2 bolts and the coolant bypass tube. Remove and discard the O-ring seal and gasket. To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
10. Clean the sealing surfaces and install a new gasket and O-ring seals.
11. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

MATERIAL CHART

Scheme 10

Scheme 11

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Disconnect the thermostat housing-to-bypass tube hose and position aside. To install, tighten to 5 Nm (44 lb-in).
4. Remove the 2 thermostat housing bolts and position aside the thermostat housing. Discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
5. Disconnect the coolant pump hose and position aside.
6. Remove the 4 coolant pump bolts and the coolant pump. To install, tighten in the following sequence: Tighten the coolant pump center bolt to 4 Nm (35 lb-in). Loosely install the 3 coolant pump outer bolts. Tighten the coolant pump center bolt to 25 Nm (18 lb-ft). Tighten the 3 coolant pump outer bolts to 10 Nm (89 lb-in).
7. To install, reverse the removal procedure. Install a new sealing washer on the center coolant pump bolt. Install a new O-ring seal on the thermostat housing and lubricate with clean engine coolant.
8. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 12

Scheme 13

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/five-hundred/i-2004-2007/remont/removal-installation/#intake-air-distribution-system-filtering-system) .
3. Remove the cooling fan motor and shroud. For additional information, refer to «COOLING FAN MOTOR AND SHROUD»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the front grille. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(/ford/five-hundred/i-2004-2007/remont/exteriorinterior-trim/#exterior-trim-and-ornamentation) .
5. Disconnect the upper radiator hose and position aside.
6. Disconnect the lower radiator hose and position aside.
7. Disconnect the horn assembly electrical connector.
8. Remove the horn assembly bolt and the horn assembly. To install, tighten to 10 Nm (89 lb-in).
9. Remove the 2 A/C condenser retaining bolts and position aside the A/C condenser. To install, tighten to 6 Nm (53 lb-in).
10. Remove the 2 radiator support bracket bolts. To install, tighten to 6 Nm (53 lb-in).
11. Remove the 2 radiator support brackets and position the radiator forward.
12. Remove the transmission cooler bracket bolt. To install, tighten to 6 Nm (53 lb-in).
13. Lift the transmission cooler off the retainers and position aside.
14. Remove the radiator.
15. To install, reverse the removal procedure.
16. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 14

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/five-hundred/i-2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Disconnect the 2 coolant hose retainers from the fan shroud and position aside.
3. Disconnect the cooling fan motor electrical connector.
4. Remove the 2 cooling fan motor and shroud bolts and release the cooling fan motor and shroud from the lower brackets. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure.

Scheme 15

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Disconnect the upper degas bottle hose and position aside.
3. Disconnect the lower degas bottle hose and position aside.
4. Remove the 2 degas bottle bolts and position aside to access the electrical connector. To install, tighten to 9 Nm (80 lb-in).
5. Disconnect the degas bottle electrical connector and remove the degas bottle.
6. To install, reverse the removal procedure.
7. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/five-hundred/i-2004-2007/remont/cooling-system-mechanical/#engine-cooling-system) .

See also:
• INTRODUCTION - GASOLINE
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• ENGINE SYSTEM-GENERAL INFORMATION
• INSTRUMENT CLUSTER
• JACKING & LIFTING
• BATTERY, MOUNTING AND CABLES
• INTAKE AIR DISTRIBUTION & FILTERING
• EXTERIOR TRIM AND ORNAMENTATION
• PROCEDURE
• GENERIC ELECTRONIC MODULE (GEM) DIAGNOSTIC TROUBLE CODE (DTC) INDEX
• SYMPTOM CHART
• Thermostat
• GENERAL SPECIFICATIONS
• Pressure Test