Engine Cooling: Other Ford Thunderbird XI

Cap

1. Remove the pressure relief cap from the degas bottle.
2. 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 the Radiator/Heater Core Pressure Tester.
3. Immerse the filler neck seal in water and install it in the filler neck adapter.
4. Install the filler neck adapter with the filler neck seal to the Radiator Cap Adapter.
5. Connect the female quick-connect fitting of the pressure test pump to the male quick-connect fitting of the filler neck adapter.
6. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained.
7. 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.
8. 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 cooling system Pressure Test.

Thermostat-Water

A new water thermostat should be installed only after the following 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 Rotunda 73 Digital Multimeter. It may be used to monitor sensor voltage values between 0-5 volts.
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 two minutes, then record the CHT voltage. Record the CHT voltage every 60 seconds. When the CHT 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. COOLANT TEMP/CHT SPECIFICATIONS Coolant Temp °C (°F) CHT Min (Volts) CHT Nom (Volts) CHT Max (Volts) 0 (32) 4.7714 4.8032 4.8723 25 (77) 4.3428 4.4148 4.4727 50 (122) 3.5354 3.6495 3.7473 80 (176) 2.3049 2.4201 2.5260 110 (230) 1.3021 1.3808 1.4562 140 (284) 0.6960 0.7414 0.7857 170 (338) 0.3784 0.4024 0.4261
5. If the thermostat opening voltage is less than 2.3049 volts and less than 80°C (176°F), install a new water thermostat.
6. If the thermostat opening voltage is greater than 2.3049 volts 82°C (180°F), the water thermostat is good and a new water thermostat should not be installed. Go to «SYMPTOM CHART»(ref-204560-S24180862262005111300000) .

Thermostat-Mechanical Test

1. Remove the water thermostat.
2. Check the water thermostat for seating. Hold the water thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates a new water thermostat should be installed. Some water thermostats have a small leakage notch at one location on the perimeter of the thermostat valve, which is considered normal.
3. Immerse the water thermostat in a boiling antifreeze and water mixture.
4. See the «GENERAL SPECIFICATIONS»(ref-204560-S17287513302005111300000) chart for water thermostat opening temperatures.

Hydraulic Cooling Fan Reservoir

1. Reduce the fluid in the reservoir by half.
2. Attach the scan tool to the vehicle.
3. Start the engine and command MAX fan.
4. Maintain 2,500 RPM. Fluid should be observed through the reservoir returning. The internal return also functions as a relief valve; fluid must be observed through the sides of the return. If the fluid is not returning through the sides, the screen is plugged. If no or little return is observed or the fluid is returning through the pressure relief, install a new reservoir.

Hydraulic Cooling Fan Motor

1. Inspect the fan blade and shroud for any foreign materials. Clear the obstruction and continue the test procedure.
2. Rotate the fan to see if any contact between the shroud and blade exists. If contact is observed, install a new fan shroud assembly.
3. Rotate the fan by hand. The fan should rotate freely (no resistance should be felt, the fan will free wheel with minimum effort). If any resistance is present, install a new fan assembly.
4. Attempt to move the fan blade and shaft in and out and side to side. If any movement is detected install a new fan assembly.

Hydraulic Cooling Fan Pump

1. Install the power steering analyzer at the high pressure port of the hydraulic cooling fan pump. Make sure the power steering analyzer gate is fully open.
2. Check the cooling fan hydraulic fluid level. If necessary, add fluid. Use Mercon(R) Multi-Purpose (ATF) Transmission Fluid XT-2-QDX meeting Ford specification Mercon(R) or equivalent.
3. Remove the reservoir screen and place the dial thermometer in the hydraulic cooling fan reservoir.
4. Start the engine and allow the engine to warm up until the fan turns on.
5. Allow fluid temperature to reach 74-80°C (165-175°F).
6. Record the flow rate and pressure readings.
7. Turn the A/C on MAX, and record the flow and pressure readings. The flow and pressure readings should increase. If the flow and pressure readings do not increase, install a new hydraulic cooling fan pump.
8. Partially close the gate valve to achieve 300 psi (2,068.5 kPa). The flow rate should be 1.65 +/-.25 GPM. If the flow rate is less than specified, install a new hydraulic cooling fan pump.

Scheme 36

Material

MATERIAL SPECIFICATION

Filling & Bleeding With RADKITPLUS

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

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Remove the engine fill cap.
2. Open the heater air bleed.
3. Add coolant to the degas bottle, allowing the system to equalize until no more coolant can be added.
4. Replace the degas bottle cap.
5. Add as much coolant as possible to the engine fill. The heater air bleed will remain open.
6. Replace the engine fill cap.
7. Start the engine and turn the heater to MAX position.
8. Close the heater air bleed when a steady stream of coolant comes from it, during engine idle.
9. Allow the engine to idle for five minutes, add coolant to the degas bottle as needed to maintain the cold fill MAX mark.
10. Reopen the heater air bleed to release any entrapped air and close again.
11. Maintain engine speed of 2,000 RPM for 3-5 minutes or until hot air comes from the heater.
12. Return to idle and verify hot air is still coming from the heater.
13. Set the heater temperature setting to 24°C (75°F) and allow the vehicle to idle for two minutes.
14. Shut the engine off and allow to cool.
15. After the engine has cooled, add coolant to the degas bottle to bring the level to the cold fill MAX mark.

Scheme 42

MATERIAL SPECIFICATION

Note. It is not uncommon to repeat this procedure three times.

Scheme 43

1. Fill the hydraulic cooling fan reservoir to the MAX level. Use Motorcraft Mercon(R) Multi-Purpose (ATF) Transmission Fluid.
2. Apply vacuum for two to three minutes. Remove the vacuum pump.
3. Start the engine and turn the A/C on MAX. This will run the hydraulic fan. If a whining noise is heard, repeat the procedure.

Scheme 44

MATERIAL SPECIFICATION

1. Once pressure is released, remove the pressure relief cap.
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .
3. Remove the water thermostat. For additional information, refer to «THERMOSTAT»(ref-204560-S37916203762005111300000) .
4. Install the water hose connection without the water thermostat.
5. Use cooling system Pro Flush and Fill, Flush Kit and Drain Kit to flush the engine and radiator.
6. Install the water thermostat.
7. Backflush the heater core if necessary. For additional information, refer to «HEATER CORE BACKFLUSHING»(ref-204560-S12764362382005111300000) .
8. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .

Scheme 45

MATERIAL SPECIFICATION

1. Once pressure is released, remove the pressure relief cap.
2. Partially drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .
3. Use cooling system Pro Flush and Fill, Flush Kit and Drain Kit to backflush the heater core.
4. Fill the cooling system. For additional information, refer to «COOLING - SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .

Scheme 46

Scheme 47

1. Remove the air cleaner outlet tube.
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .
3. Disconnect and position the lower radiator hose aside.
4. Remove the bolts and housing.
5. Remove the thermostat and the O-ring.
6. To install, reverse the removal procedure.

Scheme 48

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Scheme 50

1. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .
2. Remove the intake manifold. For additional information, refer to «ENGINE»(ref-204559) .
3. Disconnect the lower radiator hose from the thermostat housing and position aside.
4. Disconnect the hoses.
5. Remove the coolant outlet pipe. For additional information, refer to «COOLANT OUTLET PIPE»(ref-204560-S37312870712005111300000) .
6. Remove the four bolts and the thermostat housing.
7. To install, reverse the removal procedure.

Scheme 51

Scheme 52

Scheme 53

1. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .
2. Remove the air cleaner outlet tube.
3. Remove the upper radiator hose.
4. Disconnect the hoses.
5. Remove the four bolts.
6. Remove the coolant outlet pipe.
7. Remove the O-ring seals, inspect and clean the sealing surfaces.
8. To install, reverse the removal procedure.

MATERIAL SPECIFICATION

Scheme 54

Scheme 55

1. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING & BLEEDING»(ref-204560-S28277462832005111300000) .
2. Loosen the water pump pulley bolts.
3. Remove the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-139103) .
4. Remove the water pump pulley bolts and the pulley.
5. Remove the five bolts and the water pump.
6. Remove the gasket and discard. Inspect the O-ring seal. Install a new O-ring seal as necessary. Visually inspect the rotors in the water pump.