Engine Cooling System: Removal & Installation Ford Flex I

Removal and Installation

All engines

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-372804-S37252844852010093000000) .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
3. Remove the 2 bolts and position aside the thermostat housing. On 3.5L Gasoline Turbocharged Direct Injection (GTDI) vehicles, clean the bolts and apply Thread Sealant with PTFE before installing before installing the bolts. To install, tighten to 10 Nm (89 lb-in).
4. Remove the O-ring seal and thermostat. Clean and inspect the O-ring seal. Install a new seal if necessary.
5. NOTE: Genuine Mazda® Extended Life Coolant and Motorcraft® Specialty Green Engine Coolant are very sensitive to light. Do NOT allow these products to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes these products to degrade. NOTE: Lubricate the thermostat O-ring seal with clean engine coolant. To install, reverse the removal procedure.
6. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-372804-S37252844852010093000000) .

All engines

Removal

1. Remove the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING»(ref-372804-S40970177582010093000000) .
2. NOTE: The cylinder heads are removed for clarity.

PARTS DESCRIPTION CHART

Remove the coolant tube.

1. Remove and discard the O-ring seals.

Scheme 3

Installation

1. NOTE: Genuine Mazda® Extended Life Coolant and Motorcraft® Specialty Green Engine Coolant are very sensitive to light. Do NOT allow these products to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes these products to degrade. NOTE: Apply clean engine coolant to the O-ring seals prior to installation. NOTE: The cylinder heads are removed for clarity. Using new O-ring seals, install the coolant tube.
2. Install the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING»(ref-372804-S40970177582010093000000) .

1. NOTE: Genuine Mazda® Extended Life Coolant and Motorcraft® Specialty Green Engine Coolant are very sensitive to light. Do NOT allow these products to be exposed to ANY LIGHT for more than a day or two. Extended light exposure causes these products to degrade. NOTE: Apply clean engine coolant to the O-ring seals prior to installation. Using new O-ring seal, rotate the coolant tube clockwise one full turn while installing.
2. Connect the 2 LH turbocharger coolant tubes.
3. Install the coolant tube bracket-to-cylinder head nut. Tighten to 10 Nm (89 lb-in).
4. Connect the turbocharger wastegate regulating valve hose.
5. Install the ground wire and the RH cylinder head ground wire bolt. Tighten to 10 Nm (89 lb-in).
6. Install the transaxle shift cable bracket and the 3 bolts. Tighten to 12 Nm (106 lb-in).
7. Attach the wiring harness pin-type retainer to the transaxle shift cable bracket.
8. Install the starter motor. For additional information, Refer to «STARTING SYSTEM»(ref-372803) .
9. Install the battery tray. For additional information, Refer to «BATTERY, MOUNTING AND CABLES»(ref-372793) .
10. Install the intake manifold. For additional information, Refer to «ENGINE - 3.5L GTDI»(ref-372750) .
11. Using 2 new sealing washers, install the 2 LH turbocharger coolant tubes and the banjo bolts. Tighten to 40 Nm (30 lb-ft).
12. Fill and bleed the cooling system. For additional information, Refer to «Cooling System Draining, Filling and Bleeding»(ref-372804-S37252844852010093000000) .
13. Install the underbody shield and the 4 retainers.

Note. During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan may cause engine failure.

Note. On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

All vehicles

Radiator - 3.5L

Radiator (View 1 of 2)

Scheme 4

PARTS DESCRIPTION CHART

Radiator (View 2 of 2)

Scheme 5

PARTS DESCRIPTION CHART

Scheme 6

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-372804-S37252844852010093000000) .
2. Remove the cooling fan motor and shroud. For additional information, refer to «COOLING FAN MOTOR AND SHROUD - 3.5L»(ref-372804-S20444842672010093000000) .
3. Remove the front bumper cover. For additional information, Refer to «BUMPERS»(ref-372811) .
4. Disconnect the upper radiator hose and lower degas bottle hose from the radiator.
5. Disconnect the lower radiator hose from the radiator.
6. NOTE: LH shown in illustration, RH similar. Lift the tabs and remove the radiator support brackets and position the radiator toward the engine.
7. Remove the 2 A/C condenser bolts from the radiator and separate the condenser from the radiator. To install, tighten to 6 Nm (53 lb-in).
8. NOTE: Make sure the bottom radiator insulators are in place when installing the radiator. Remove the radiator.
9. To install, reverse the removal procedure.
10. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-372804-S37252844852010093000000) .

Radiator - 3.5L GTDI

Radiator (View 1 of 4)

Scheme 7

PARTS DESCRIPTION CHART

Radiator (View 2 of 4)

Scheme 8

PARTS DESCRIPTION CHART

Radiator (View 3 of 4)

Scheme 9

PARTS DESCRIPTION CHART

Radiator (View 4 of 4)

Scheme 10

PARTS DESCRIPTION CHART

Scheme 11

PARTS DESCRIPTION CHART

Scheme 12

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the Air Cleaner (ACL) assembly. For additional information, Refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-372794) .
3. If equipped, detach the block heater wiring harness retainers from the engine wiring harness.
4. Disconnect the cooling fan motor electrical connector and detach all the wiring harness retainers from the shroud.
5. Detach the 3 wiring harness retainers from the radiator support.
6. Detach the hood release cable retainer from the cooling fan motor and shroud.
7. Detach the upper radiator hose from the cooling fan motor and shroud.
8. Release the tab through the access hole and remove the upper radiator hose support.
9. Remove the 2 bolts and the cooling fan motor and shroud. To install, tighten to 6 Nm (53 lb-in).
10. To install, reverse the removal procedure.

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. Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn counterclockwise. When the pressure is released, remove the pressure relief cap.
2. Using hose clamp pliers, clamp the lower degas bottle hose.
3. Using a suction device, siphon the coolant from the degas bottle.
4. Disconnect the upper and lower degas bottle hose.
5. Detach the pin-type retainer from the degas bottle.
6. If equipped, separate the power steering reservoir from the degas bottle.
7. Remove the 2 bolts and the degas bottle. To install, tighten to 9 Nm (80 lb-in).
8. To install, reverse the removal procedure.
9. Fill the degas bottle. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-372804-S37252844852010093000000) for the recommended coolant mixture and fill level.