Engine Cooling: Removal & Installation Ford Fusion I facelift

REMOVAL AND INSTALLATION

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. If equipped, remove the 7 screws and the underbody cover.
4. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
5. Remove the block heater cover.
6. Disconnect the block heater electrical connector.
7. Remove the block heater. To install, tighten to 20 Nm (177 lb-in) (2.3L only). To install, tighten to 40 Nm (30 lb-ft) (3.0L and 3.5L).
8. To install, reverse the removal procedure.
9. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. Remove the 3 bolts and reposition the thermostat housing to gain access to the hose clamps. Remove and discard the gasket. To install, tighten the bolts to 10 Nm (89 lb-in).
4. Disconnect the heater hose from the thermostat housing.
5. Disconnect the lower radiator hose from the thermostat housing and remove the thermostat housing.
6. To install, reverse the removal procedure. Install a new thermostat housing gasket.
7. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

Thermostat - 3.0L

Material

Scheme 2

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. Disconnect the upper radiator-to-thermostat housing hose and position aside.
4. Remove the 3 bolts, thermostat housing cover, O-ring seal and thermostat. Clean and inspect the O-ring seal. Install a new seal if necessary. To install, tighten to 10 Nm (89 lb-in).
5. 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-291897-S25794359812008073000000) .

Scheme 3

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V)»(ref-291911) article.
4. Disconnect the upper radiator hose from the thermostat housing and position aside.
5. Disconnect the lower radiator hose from the thermostat housing and position aside.
6. Disconnect the heater hose from the thermostat housing and position aside.
7. Reposition the 2 thermostat housing-to-engine hose clamps. Remove the thermostat housing.
8. To install, reverse the removal procedure.
9. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

Thermostat - 3.5L

Material

Scheme 4

1. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
2. Remove the air cleaner and outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L»(ref-291916) article.
3. Disconnect the lower radiator hose from the thermostat housing cover and position it aside.
4. Remove the 2 bolts, thermostat housing cover, O-ring seal and thermostat. Clean and inspect the O-ring seal. Install a new seal if necessary. To install, tighten to 10 Nm (89 lb-in).
5. 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-291897-S25794359812008073000000) .

1. Remove the thermostat. For additional information, refer to «Thermostat - 3.5L»(ref-291897-S03959846532008073000000) .
2. Disconnect the 4 coolant hoses from the thermostat housing and position them aside.
3. Remove the 2 thermostat housing bolts. To install, tighten to 10 Nm (89 lb-in).
4. Separate the thermostat housing from the coolant tube and remove the thermostat housing. Remove and discard the O-ring seals.
5. To install, reverse the removal procedure. Lubricate the new O-ring seals with clean engine coolant.

Scheme 5

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. Remove the intake manifold. For additional information, refer to «ENGINE - 2.3L»(ref-291902) article.
4. Disconnect and remove the coolant bypass tube from the engine.
5. 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-291897-S25794359812008073000000) .

1. Remove the thermostat housing. For additional information, refer to «Thermostat Housing - 3.0L»(ref-291897-S21000527182008073000000) .
2. Remove the bypass tube-to-thermostat housing hose.
3. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector.
4. Detach the wiring harness retainer from the bypass tube stud bolt.
5. Remove the bolt, stud bolt and bypass tube. To install, tighten the bolt and stud bolt to 10 Nm (89 lb-in).
6. Remove and inspect the O-ring seals, install new seals if necessary.
7. To install, reverse the removal procedure. Lubricate the O-ring seals with clean engine coolant.
8. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. Loosen the 3 coolant pump pulley bolts.
4. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-291862) article.
5. Remove the 3 bolts and the coolant pump pulley. To install, tighten to 20 Nm (177 lb-in).
6. Remove the 3 bolts and the coolant pump. Remove and discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
7. To install, reverse the removal procedure. Lubricate the O-ring seal with clean engine coolant.
8. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

REMOVAL

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
3. Remove the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-291863) article.
4. Using the Water Pump Pulley Plate, Water Pump Shaft Protector and the Crankshaft Vibration Damper Remover, remove the coolant pump pulley.
5. Disconnect the heater hose from the coolant pump.
6. Disconnect the coolant pump-to-engine hose and position aside.
7. Remove the 3 bolts from the coolant pump assembly.
8. Reposition the coolant pump-to-thermostat housing hose clamp and remove the coolant pump and hose as an assembly.

INSTALLATION

1. Connect the coolant pump-to-thermostat housing hose and reposition the clamp.
2. Position the coolant pump assembly and install the 3 bolts. Tighten to 10 Nm (89 lb-in). Tighten the 3 bolts an additional 90 degrees.
3. Connect the coolant pump-to-engine hose and the heater hose.
4. Install the Camshaft Pulley Installer on the camshaft as shown in the illustration. Adjust the collar on the Camshaft Pulley Installer to get the best thread engagement in the rear of the camshaft.
5. Position the coolant pump pulley over the previously installed Camshaft Pulley Installer on the end of the camshaft. Install the Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer as shown in the illustration. Using the Camshaft Pulley Installer, Water Pump Pulley Spacer and the Power Steering Pump Pulley Installer, install the coolant pump pulley flush with the end of the camshaft.
6. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-291863) article.
7. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

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 can cause engine failure.

1. Remove the engine front cover. For additional information, refer to «ENGINE - 3.5L»(ref-291903) article.
2. Remove and discard the engine oil filter.
3. Rotate the crankshaft clockwise and align the timing marks on the variable camshaft timing Variable Camshaft Timing (VCT) assemblies as shown.
4. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
5. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
6. Remove the 3 bolts and the RH VCT housing.
7. Remove the 3 bolts and the LH VCT housing.
8. Remove and discard the VCT housing seals.
9. Remove the 2 bolts and the primary timing chain tensioner.
10. Remove the primary timing chain tensioner arm.
11. Remove the 2 bolts and the lower LH primary timing chain guide.
12. Remove the primary timing chain.
13. Remove the 2 bolts and the upper LH primary timing chain guide.
14. Remove the RH primary timing chain guide lower bolt.
15. Loosen the RH primary timing chain guide upper bolt. Rotate the guide and tighten the bolt.
16. Place clean, lint-free shop towels in the oil pan opening to prevent coolant from entering the oil pan during coolant pump removal.
17. Remove the 8 bolts and the coolant pump.

Note. Clean and inspect all sealing surfaces.

1. Install the coolant pump and the 8 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
2. Remove all of the shop towels from the oil pan opening.
3. Remove the oil pan drain plug and allow any accumulated coolant to drain. Remove any residual coolant from the front of the engine and the oil pan using regulated, compressed air and clean, lint-free shop towels. Install the oil pan drain plug and tighten to 27 Nm (20 lb-ft).
4. Loosen the RH primary timing chain guide upper bolt. Position the RH primary timing chain guide and install the lower bolt. Tighten the 2 bolts to 10 Nm (89 lb-in).
5. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
6. Install the upper LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
7. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
8. Install the primary timing chain tensioner arm.
9. Reset the primary timing chain tensioner. Rotate the lever counterclockwise. Using a soft-jawed vise, compress the plunger. Align the hole in the lever with the hole in the tensioner housing. Install a suitable lock pin.
10. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lock pin.
11. As a post check, verify correct alignment of all timing marks.
12. Install new VCT housing seals.
13. Install the LH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
14. Install the RH VCT housing and the 3 bolts. Tighten in the sequence shown to 10 Nm (89 lb-in).
15. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
16. Install the engine front cover. For additional information, refer to «ENGINE - 3.5L»(ref-291903) article.

Scheme 6

Scheme 7

All vehicles

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the generator air inlet duct.
3. Remove the air cleaner. For additional information, refer to «INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L»(ref-291916) article.
4. Remove the 2 bolts and the air cleaner bracket. To install, tighten to 10 Nm (89 lb-in).
5. If equipped, detach the 3 block heater wiring retainers from the cooling fan motor and shroud and position aside.
6. Remove the splash shield.
7. Detach the lower radiator hose from the cooling fan motor and shroud.
8. Detach the retainer on the lower radiator hose from the cooling fan motor and shroud.
9. If equipped, detach the transmission cooler tubes from the cooling fan motor and shroud.
10. Detach the wiring harness retainers and position the harness aside.
11. Disconnect the cooling fan electrical connector.
12. Release the 2 tabs and remove the cooling fan motor and shroud.
13. To install, reverse the removal procedure.

Scheme 8

Scheme 9

All vehicles

1. Drain the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .
2. Remove the cooling fan motor and shroud. For additional information, refer to «Cooling Fan Motor and Shroud»(ref-291897-S38202474752008073000000) .
3. Detach the power steering hose retainer from the radiator.
4. Disconnect the upper radiator hose from the radiator.
5. Detach the retainer from the radiator.
6. Disconnect the radiator-to-degas bottle hose from the radiator.
7. Disconnect the 2 transmission cooling tubes from the radiator. To install, tighten to 30 Nm (22 lb-ft).
8. Disconnect the lower radiator hose from the radiator.
9. Lift and remove the tabs from the upper radiator support and position the radiator towards the engine.
10. Remove the A/C condensor-to-radiator pin-type retainer.
11. Squeeze the tabs and separate the A/C condenser from the radiator. Remove the radiator.
12. To install, reverse the removal procedure.
13. Fill and bleed the cooling system. For additional information, refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) .

Scheme 10

Scheme 11

All vehicles

1. 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 suitable suction device, siphon the coolant from the degas bottle.
4. If equipped, detach the wiring retainer from the degas bottle.
5. Disconnect the degas bottle-to-radiator hose and position aside.
6. Disconnect the degas bottle-to-thermostat housing hose and position aside.
7. Disconnect the lower degas bottle hose and position aside.
8. Remove the nut, bolt and the degas bottle. To install, tighten to 9 Nm (80 lb-in).
9. To install, reverse the removal procedure.
10. Fill the degas bottle. Refer to «Cooling System Draining, Filling and Bleeding»(ref-291897-S25794359812008073000000) for the recommended coolant mixture and fill level.