Engine Cooling Lincoln Zephyr US

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Note. The addition of Cooling System Stop Leak Pellets or equivalent meeting Ford specification WSS-M99B37-B6 darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

The cooling system components are the

1. Radiator.
2. Bypass tube.
3. Pressure relief cap.
4. Gades bottle.
5. Radiator draincock.
6. Coolant pump.
7. Engine coolant temperature indicator unit.
8. Thermostat.
9. Engine coolant temperature sensor.
10. Variable speed fan motor assembly.
11. Fan control module.

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 engine coolant and distilled water.

To maintain the integrity of the coolant and the cooling system

1. Add Motorcraft Premium Gold Engine Coolant 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 or equivalent meeting Ford specification WSS-M97B44-D or green colored Motorcraft Premium Engine Coolant meeting Ford specification ESE-M97B44-A or equivalent. 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.

Fail Safe Cooling (2.3L only)

The vehicle has a strategy built into the powertrain control module (PCM) that will control the engine if it starts to overheat.

Stage 1 of the strategy will commence if the engine starts to overheat. The cylinder head temperature (CHT) sensor transmits a signal to the PCM, which then moves the temperature gauge pointer into the red zone.

If the engine is not switched OFF and the temperature continues to rise, the powertrain check lamp is illuminated. This indicates to the driver that the engine is approaching critical limits and should be stopped. At this point DTC P1285 is set in the PCM which can be retrieved using a diagnostic tool.

Stage 2 of the strategy will commence if the lamp and temperature gauge are ignored by the driver. The PCM will start to control the engine by cutting out cylinders and restricting the RPM to below 3,000 RPM. Simultaneously the malfunction indicator lamp (MIL) will be illuminated. This indicates that long term engine damage can occur and vehicle emissions will be affected. At this point DTC 1299 is set in the PCM which can be retrieved using a diagnostic tool.

Air is then drawn into the deactivated cylinders. This helps to control the temperature of the engine internal components. The deactivated cylinders are alternated to allow even cooling of all the cylinders.

Note. If the driver is using a high percentage of throttle travel (for example, an overtaking maneuver) when the PCM starts, engine deactivation will be delayed for 10 seconds.

Note. After the cylinder deactivation operation has begun, the engine will not revert to operating on all cylinders, even if the temperature should fall, until the ignition is switched OFF and then ON again.

Note. The malfunction indicator lamp can only be extinguished by using a scan tool after the fault has been rectified and the DTC cleared.

Stage 3 of the strategy will commence if the engine temperature still continues to rise. This will result in the engine being totally disabled before major engine damage or seizure occurs. The powertrain check lamp will begin to flash, indicating to the driver that the engine will be switched OFF after 30 seconds. This allows the driver time to choose a suitable parking place.

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 1

Scheme 2

SPECIAL TOOL(S) CHART Pressure Test Kit 014-R1072 or equivalent Battery/Antifreeze Tester 014-R1060 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware or equivalent scan tool 73III Automotive Meter 105-R0057 or equivalent

Scheme 3

Scheme 4

MATERIAL CHART

Principles of Operation

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley which is driven by the accessory drive belt, a belt driven by a pulley attached to the camshaft, or a sprocket driven by the timing chain to circulate the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine generated heat to the outside air.

Note. The vehicle is equipped with either a degas bottle or an expansion tank.

The degas bottle, if equipped, holds surplus coolant and removes air from the cooling system, which reduces hot spots. It also allows for coolant expansion and system pressurization, replenishes coolant to the cooling system and serves as the location for service fill.

The coolant expansion tank, if equipped, holds surplus coolant, allows for coolant expansion and replenishes coolant to the cooling system. It is equipped with a non-pressurized cap which allows coolant to be added to the tank to keep it filled to prescribed levels.

The cooling fan draws air through the radiator to help cool the system coolant as it passes through the radiator.

The thermostat monitor is a function of the powertrain control module (PCM) and is designed to verify correct thermostat operation. The monitor will be executed once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction occurs, diagnostic trouble code (DTC) P0125 or P0128 is set, and the malfunction indicator lamp will be illuminated.

For vehicle/engine specific information, refer to ENGINE COOLING .

Inspection and Verification

Note. Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

1. Verify the customer concern.
2. Visually check the engine coolant level at the degas bottle or coolant expansion tank when the system is cold.
3. Make sure the pressure relief cap is installed correctly.
4. Record any cooling system diagnostic trouble codes (DTCs) retrieved. Refer to the «DTC CHART»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) for DTC descriptions.
5. If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved, verify the customer's concern by operating the engine to duplicate the condition.
6. Inspect to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION CHART Mechanical Electrical Leaks or weeps at: Hoses Tubes Clamp joints Quick connect couplings (if equipped) Gaskets O-rings Thermostat housing Radiator Pressure relief cap Coolant pump Heater core (wet floor or coolant odor in vehicle) Heater control valve Heated throttle body or heated throttle body adapter (if equipped) Coolant crossover manifold assembly (if equipped) Oil cooler (if equipped) Degas bottle (if equipped) Coolant expansion tank (if equipped) Heated positive crankcase ventilation (PCV) (if equipped) Fuel pressure regulator Clayton bowl (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) Cracked or damaged: Hoses Tubes Hose clamps Heater control valve (if equipped) Thermostat housing Radiator Pressure relief cap Cooling fan Fan clutch (if equipped) Coolant pump Degas bottle (if equipped) Coolant expansion tank (if equipped) Oil cooler (if equipped) Coolant crossover manifold assembly (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) Restricted airflow through the A/C condenser/radiator Drive belt loose, worn or installed incorrectly Broken or weak drive belt tensioner Excessive white or light gray exhaust smoke (may have burnt coolant odor) Coolant in engine oil Engine oil in coolant Coolant in automatic transmission fluid (if equipped) Automatic transmission fluid (if equipped) in coolant Inoperative or damaged: Electric cooling fan (if equipped) Electronically actuated fan clutch Electronically actuated fan clutch controller Wiring, connectors, relays or modules Engine coolant temperature (ECT) sensor (if equipped) Cylinder head temperature (CHT) sensor (if equipped) Intake air temperature (IAT) sensor (if equipped) Mass air flow (MAF) sensor Vehicle speed sensor (VSS)
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test the system for normal operation.
8. Inspect the coolant condition. Inspect the coolant color. If Motorcraft Premium Gold Engine Coolant has a clear or pale yellow color, this indicates higher water content than required. Test the engine coolant freezing point range with the Battery/Anti-Freeze Tester. The freezing point should be in the range -45°C to -23°C (-50°F to -10°F). If the vehicle is driven in cold climates less than -36°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. A pale green color indicates incorrect coolant (green in color) may have been added to the system. Use of incorrect (green in color) coolant degrades the corrosion protection of Motorcraft Premium Gold Engine Coolant. Flush the system and refill with the correct mixture of distilled water and Motorcraft Premium Gold Engine Coolant. NOTE: If Cooling System Stop Leak Pellets are used, darkening of the Motorcraft Premium Gold Engine Coolant from yellow to golden tan will occur. Dark brown could indicate a commercially available stop leak may have been used. Flush the system and refill with the correct mixture of distilled water and Motorcraft Premium Gold Engine Coolant. A light or reddish brown color indicates that rust may be present in the cooling system. Flush the system and refill with the correct mixture of distilled water and Motorcraft Premium Gold Engine Coolant. An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For information on engine diagnosis, refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) . A milky brown color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to «COMPONENT TESTS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . If engine oil is suspected, the cause of the leak may be internal to the engine. Refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) . A red, orange or light green colored sheen on top of the coolant may indicate that transmission fluid is entering the cooling system. The cause may be a leaky radiator. Pressure test the cooling system. Refer to the «COMPONENT TESTS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the Battery/Anti-Freeze Tester. The freezing point should be in the range -45°C to -23°C (-50°F to -10°F). If the vehicle is driven in cold climates less than -36°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. Maximum coolant concentration is 60/40 for cold weather areas. Minimum coolant concentration is 40/60 for warm weather areas. Adjust coolant range and level if necessary: If coolant is low, add specified coolant mixture only. If the engine coolant tests too weak, remove some of the engine coolant and add undiluted engine coolant until the readings are within acceptable levels. If the engine coolant tests strong, remove some of the engine coolant and add distilled water until the readings are within acceptable levels.
9. If an obvious cause for an observed or reported concern is found, correct the cause and test the system for normal operation before proceeding to the next step.
10. If the cause is not visually evident, connect the scan tool to the data link connector (DLC).
11. If the scan tool does not communicate with the VCM: Check the VCM connection to the vehicle. Check the scan tool connection to the VCM. Refer to «MODULE COMMUNICATIONS NETWORK»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) , No Power To The Scan Tool, to diagnose no communication with the scan tool.
12. If the scan tool does not communicate with the vehicle: Verify the ignition key is in the ON position. Verify the scan tool operation with a known good vehicle. Refer to «MODULE COMMUNICATIONS NETWORK»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) to diagnose no response from the powertrain control module (PCM).
13. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#module-communications-network) . If the network test passes, retrieve and record continuous memory diagnostic trouble codes (DTCs).
14. Clear the continuous DTCs and carry out the self-test diagnostics for the generic electronic module (GEM).
15. If the DTCs recovered are related to the concern, go to the . For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC CONTROL MODULES»(/lincoln/zephyr/us-2006-2006/remont/communication-devices/#multifunction-electronic-control-modules) .
16. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__symptom-chart) .

Powertrain Control Module (PCM) DTC Chart

POWERTRAIN CONTROL MODULE (PCM) DTC CHART

Symptom Chart

SYMPTOM CHART

Normal Operation

The engine cooling system is a closed system that provides for coolant expansion and contraction and also changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and clamps are used to contain coolant within the cooling system and keep other fluids and contaminants from entering the cooling system.

Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.

For vehicle/engine specific information, refer to ENGINE COOLING .

This pinpoint test is intended to diagnose the following

1. Coolant hoses or tubes
2. Hose clamps
3. Thermostat O-ring seal or gasket
4. Coolant pump O-ring seal or gasket
5. Thermostat housing
6. Heater control valve (if equipped)
7. Radiator
8. Transmission fluid cooler (in radiator) (if equipped)
9. Pressure relief cap
10. Coolant pump leaking from weep hole
11. Auxiliary coolant pump (if equipped)
12. Heater core
13. Heated throttle body or heated throttle body adapter (if equipped)
14. Coolant crossover manifold assembly (if equipped)
15. Engine gaskets
16. Oil cooler (if equipped)
17. Degas bottle (if equipped)
18. Coolant expansion tank (if equipped)
19. Heated positive crankcase ventilation (PCV) (if equipped)
20. Fuel pressure regulator coolant bowl (if equipped)
21. Cylinder block core plugs (if equipped)
22. Cylinder head core plugs (if equipped)
23. Block heater (if equipped)
24. Engine coolant temperature (ECT) sensor (if equipped)

PINPOINT TEST A: LOSS OF COOLANT

1. A1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__inspection-and-verification) procedure. Were any concerns found? Yes : REPAIR as needed. TEST the system for normal operation. No : GO to A2.
2. A2 CHECK THE ENGINE COOLANT LEVEL NOTE: Allow the engine to cool before checking the engine coolant level. Key in OFF position. Visually inspect the engine coolant level at the degas bottle or the coolant expansion tank. Is the engine coolant level within specifications? Yes : GO to A3. No : ADJUST the engine coolant level as necessary. GO to A3.
3. A3 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to «COMPONENT TESTS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . Does the engine cooling system leak? Yes : REPAIR or INSTALL new components. TEST the system for normal operation. No : If the vehicle is equipped with a coolant expansion tank, GO to A4. If the vehicle is equipped with a degas bottle, GO to A5 .
4. A4 CHECK THE PRESSURE RELIEF CAP Carry out the pressure relief cap pressure test. Refer to «COMPONENT TESTS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . Is the pressure relief cap OK? Yes : GO to A5. No : INSTALL a new pressure relief cap. TEST the system for normal operation.
5. A5 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle or coolant expansion tank for signs of engine oil or transmission fluid. Is engine oil or transmission fluid evident in the coolant? Yes : If engine oil is evident, GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) for engine diagnosis. If transmission fluid is evident, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate article for the procedure. TEST the system for normal operation. No : GO to A6.
6. A6 CHECK THE ENGINE OIL AND TRANSMISSION FLUID FOR COOLANT Remove the oil level indicators from the engine and the transmission. Is coolant evident in the oil or transmission fluid? Yes : If coolant is in the engine oil, GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) . If coolant is in the transmission fluid, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate article for the procedure. No : GO to A7.
7. A7 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use U-View® Combustion Leak Tester part number 560000 or equivalent. Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases. Are combustion gases present? Yes : GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) for engine diagnosis. No : The cooling system is operational.

The engine cooling system functions to maintain engine temperatures during operation. Proper coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a proper engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley which is driven by the accessory drive belt, a belt driven by a pulley attached to the camshaft, or a sprocket driven by the timing chain to circulate the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine generated heat to the outside air.

Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at the proper rate, the inability to transfer heat from the engine through the coolant (including low coolant), or an inability to transfer engine generated heat to the outside air through the radiator.

For vehicle/engine specific information, refer to ENGINE COOLING .

1. DTC P0217 Engine Coolant (ECT) Over Temperature Condition
2. DTC P1285 Cylinder Head Over Temperature (CHT) Condition
3. DTC P1299 Cylinder Head Over Temperature Protection Active

This pinpoint test is intended to diagnose the following

1. Low coolant level
2. External engine coolant leak
3. Airlock in system
4. Pressure relief cap installation
5. Restricted airflow through the A/C condenser/radiator
6. Internal engine coolant leak
7. Coolant condition/concentration
8. Accessory drive components
9. Non-OEM engine enhancement components
10. Electric cooling fan (if equipped)
11. Mechanical cooling fan blade (if equipped)
12. Mechanical cooling fan clutch (if equipped)
13. Engine coolant temperature indicator system (gauge)
14. Engine coolant temperature (ECT) sensor (if equipped)
15. Cylinder head temperature (CHT) sensor (if equipped)
16. Heater core
17. Coolant pump
18. Coolant flow restriction

PINPOINT TEST B: THE ENGINE OVERHEATS

1. B1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__inspection-and-verification) procedure. Were any concerns found? Yes : REPAIR as needed. TEST the system for normal operation. No : GO to B2.
2. B2 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) NOTE: Refer to the «INTRODUCTION - GASOLINE»(ref-249149) article for correct scan tool hook-up procedure. Check for DTCS P0217, P1285 or P1299. Is DTC P0217, P1285 or P1299 present? Yes : GO to B3. No : Actual engine overheating has not been verified. CHECK the engine coolant temperature gauge operation. REFER to «INSTRUMENT CLUSTER»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-cluster) . If any other DTCs are retrieved, REFER to the «INTRODUCTION - GASOLINE»(ref-249149) article.
3. B3 CHECK FOR AN AIRFLOW OBSTRUCTION Check the radiator or A/C condenser for an obstruction such as leaves or cardboard. Is an obstruction present? Yes : REMOVE the obstruction. TEST the system for normal operation. No : GO to B4.
4. B4 CHECK THE ENGINE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant level. Key in OFF position. Visually check the engine coolant level in the degas bottle or coolant expansion tank. Is the engine coolant level within specification? Yes : GO to B5. No : ADJUST the engine coolant level as necessary. GO to B5.
5. B5 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to «COMPONENT TESTS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . Does the engine cooling system leak? Yes : REPAIR or INSTALL new components. TEST the system for normal operation. No : Vehicles equipped with an expansion tank, GO to B6. Vehicles equipped with a degas bottle, GO to B7 .
6. B6 CHECK THE PRESSURE RELIEF CAP Carry out the pressure relief cap pressure test. Refer to «CAP»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cap) . Is the pressure relief cap OK? Yes : GO to B7. No : INSTALL a new pressure relief cap. TEST the system for normal operation.
7. B7 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle or coolant expansion tank for signs of engine oil or transmission fluid. Is engine oil or transmission fluid evident in the coolant? Yes : If engine oil is evident, GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) for engine diagnosis. If transmission fluid is evident, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate article for the procedure. TEST the system for normal operation. No : GO to B8.
8. B8 CHECK THE ENGINE OIL AND TRANSMISSION FLUID FOR COOLANT Remove the oil level indicators from the engine and the transmission. Is coolant evident in the oil or transmission fluid? Yes : If coolant is in the engine oil, GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) . If coolant is in the transmission fluid, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate article for the procedure. No : GO to B9.
9. B9 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use U-View® Combustion Leak Tester part number 560000 or equivalent. Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases. Are combustion gases present? Yes : GO to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) for engine diagnosis. No : GO to B10
10. B10 CHECK COOLANT CONDITION Check the coolant for dirt, rust or contamination and check the coolant concentration. Is the coolant condition OK? Yes : Vehicles equipped with an electric cooling fan, GO to B11. Vehicles equipped with only a mechanical cooling fan, GO to B12 . No : FLUSH the engine cooling system. REFER to «COOLING SYSTEM FLUSHING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-flushing) . TEST the system for normal operation.
11. B11 CHECK THE ELECTRIC COOLING FAN OPERATION Start the engine. Place the climate control function selector in the MAX A/C position and the blower motor switch in the HI position. Did the electric cooling fan operate? Yes : If the vehicle is also equipped with a mechanical cooling fan, GO to B12. Otherwise, GO to B13 . No : DIAGNOSE the electric cooling fan operation. REFER to «INTRODUCTION - GASOLINE»(ref-249149) article.
12. B12 CHECK THE MECHANICAL COOLING FAN OPERATION Key in OFF position. If the vehicle is equipped with a viscous fan clutch, carry out the «FAN CLUTCH TEST»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__fan-clutch-test) . If the vehicle is equipped with an electronically actuated fan clutch, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. Is the cooling fan operation OK? Yes : GO to B13. No : INSTALL a new fan clutch. TEST the system for normal operation.
13. B13 CHECK THE COOLANT PUMP OPERATION Start the engine. Allow the engine to run for 10 minutes (hot side thermostat equipped vehicles) or 30 minutes (cold side thermostat equipped vehicles). Place the climate control function selector in the MAX HEAT position. Feel the heater outlet hose. Is the heater outlet hose hot? Yes : GO to B14. No : INSTALL a new coolant pump. TEST the system for normal operation.
14. B14 CHECK THE THERMOSTAT OPERATION Start the engine. Allow the engine to run for 10 minutes (hot side thermostat equipped vehicles) or 30 minutes (cold side thermostat equipped vehicles). Feel the upper radiator hose (hot side thermostat equipped vehicles) or the lower radiator hose (cold side thermostat equipped vehicles). Is the upper (hot side thermostat equipped vehicles) or lower (cold side equipped vehicles) radiator hose hot? Yes : CHECK the engine coolant temperature gauge operation. REFER to «INSTRUMENT CLUSTER»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-cluster) . No : GO to B15.
15. B15 VISUALLY INSPECT THE THERMOSTAT Carry out the «THERMOSTAT VISUAL INSPECTION»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__thermostat-visual-inspection) . Is the thermostat damaged? Yes : INSTALL a new thermostat. TEST the system for normal operation. No : INSTALL a new thermostat. TEST the system for normal operation. If the engine still overheats, INSTALL a new radiator. TEST the system for normal operation.

The engine cooling system functions to maintain engine temperatures during operation. Proper coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a proper engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley which is driven by the accessory drive belt, a belt driven by a pulley attached to the camshaft, or a sprocket driven by the timing chain to circulate the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine generated heat to the outside air.

Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant flow through some coolant circuits (radiator, heater core) is more than expected given the conditions, or when the cooling fans operate all the time (electric fans) or the fan clutch is always engaged (engine driven fans). Heat is not allowed to build in the engine because a heat exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition, perceived concerns that the engine does not reach normal operating temperature can be related to a low coolant level or trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.

For vehicle/engine specific information, refer to ENGINE COOLING .

1. DTC P0125 Insufficient Coolant Temperature (ECT) For Closed Loop Fuel Control
2. DTC P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature)

This pinpoint test is intended to diagnose the following

1. Low coolant level
2. Thermostat
3. Engine coolant temperature (ECT) indicator system (gauge)
4. Engine cooling fan

PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

1. C1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__inspection-and-verification) procedure. Were any concerns found? Yes : REPAIR as needed. TEST the system for normal operation. No : GO to C2.
2. C2 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0125 or P0128 NOTE: Refer to the «INTRODUCTION - GASOLINE»(ref-249149) article for correct scan tool hook-up procedure. Check for DTCs P0125 or P0128. Is DTC P0125 or P0128 present? Yes : If the vehicle is equipped with an electric cooling fan, GO to C3. If the vehicle is equipped with only a mechanical cooling fan, GO to C4 . No : The cooling system is operational. If an inoperative engine coolant temperature gauge is suspected, CHECK the engine coolant temperature gauge operation. REFER to «INSTRUMENT CLUSTER»(/lincoln/zephyr/us-2006-2006/remont/gauges-instrument-panels/#instrument-cluster) . If an inoperative climate control system is suspected, CHECK the climate control system operation. REFER to «CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS»(/lincoln/zephyr/us-2006-2006/remont/automatic-hvac-system/#climate-control-system-general-information-and-diagnostics) . If any other DTCs are retrieved, REFER to the «INTRODUCTION - GASOLINE»(ref-249149) article.
3. C3 CHECK THE ELECTRIC COOLING FAN OPERATION Allow the engine to cool. Make sure the A/C switch is OFF (if equipped). Start the engine. Check the electric cooling fan. Is the electric cooling fan on all the time? Yes : DIAGNOSE the electric cooling fan operation. REFER to the «INTRODUCTION - GASOLINE»(ref-249149) article. No : If the vehicle is also equipped with a mechanical cooling fan, GO to C4. Otherwise, GO to C5 .
4. C4 CHECK THE MECHANICAL COOLING FAN OPERATION Carry out the «FAN CLUTCH TEST»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__fan-clutch-test) . For a mechanical cooling fan clutch, refer to «COMPONENT TESTS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . For an electronic cooling fan clutch, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. Is the cooling fan clutch OK? Yes : GO to C5. No : INSTALL a new cooling fan clutch. TEST the system for normal operation.
5. C5 CHECK THE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant level. Visually check the engine coolant level in the degas bottle or coolant expansion tank. Is the engine coolant level within specification? Yes : INSTALL a new thermostat. TEST the system for normal operation. No : GO to «PINPOINT TEST A»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__pinpoint-test-a-loss-of-coolant) to diagnose a coolant leak.

Pressure Test - Degas Bottle Systems

Note. Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

1. Turn the engine OFF.
2. Check the engine coolant level. Adjust the coolant level as necessary.
3. Attach 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. If the pressure reading exceeds the maximum cap pressure listed in the specifications table, install a new pressure relief cap.
5. If the system does not hold pressure, remove the pressure relief cap and wash in clean water to dislodge all the foreign material from the gasket. Check the sealing surface in the filler neck of the degas bottle for nicks or cuts. Install the pressure relief cap.
6. Pressurize the engine cooling system as described in Step 4 above. Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.
7. If no leaks are found and the pressure drops, the pressure relief cap may be leaking. Install a new pressure relief cap and retest the system.
8. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as necessary.
9. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) to diagnose the engine.
10. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as necessary.

Pressure Test - Coolant Expansion Tank Systems

Note. Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

1. Turn the engine OFF.
2. Remove the pressure relief cap. Top off the radiator as needed. Fit the pressure tester to the radiator fill neck.
3. Pump the cooling system to a maximum of 138 kPa (20.0 psi) and hold for 2 minutes. If the pressure drops within this time, inspect for leaks and repair as necessary.
4. If no leaks are found and the pressure drops, the leak may be internal to the radiator transmission cooler (if equipped). Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as necessary.
5. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to «ENGINE SYSTEM-GENERAL INFORMATION»(/lincoln/zephyr/us-2006-2006/remont/mechanical/#engine-system-general-information) to diagnose the engine.

Cap

1. Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap if necessary.
2. Fit the pressure relief cap to the Radiator/Heater Core Pressure Tester Kit using the correct adapter.
3. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release the pressure and repeat the test. Install a new pressure relief cap if the pressure is not within specification. Refer to the «GENERAL SPECIFICATIONS»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .

Thermostat

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

1. Pinpoint Test A, B or C
2. Thermostat Visual Inspection

Thermostat Visual Inspection

1. Remove the thermostat.
2. Examine the thermostat for signs of damage including: Valve not fully seated (light visible through the valve) Foreign material lodged in the main valve Bent or broken frame or flange Bent or broken spring Bent or broken valve or valve stem Wax leaking from wax reservoir or a bulge in the reservoir Any other damage or distortion
3. If damage is found during the inspection, remove any foreign material or broken pieces and install a new thermostat.
4. If no damage is found during the inspection, continue troubleshooting the system concern. Go to the «SYMPTOM CHART»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__symptom-chart) for further instructions.

Radiator Leak Test, Removed From Vehicle

Note. Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator.

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.

Fan Clutch Test

1. Turn the engine OFF and wait until the fan comes to a complete stop.
2. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked. For an electronically actuated fan clutch, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. For a viscous fan clutch, carry out the following

Fan Clutch Test - Minimum Speed Requirement

1. Use a suitable marker to mark the coolant pump or fan pulley and one of the fan blades.
2. Make sure the A/C is OFF, if equipped.
3. Start the engine and run it at approximately 2,000 RPM for 5 minutes or until there is a noticeable reduction in fan noise to allow the fan clutch to go into disengaged mode.
4. Aim a laser photo tachometer at the coolant pump or fan pulley. Run the engine to achieve 3,000 RPM at the coolant pump or fan pulley.
5. With the coolant pump or fan pulley at 3,000 RPM, aim the laser photo tachometer at the fan blade. Monitor and record fan speed.
6. The fan blade speed must be less than the specified RPM at 3,000 RPM coolant pump or fan pulley RPM. Refer to the «SPECIFICATION TABLE»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) for correct fan speed.
7. Turn the engine off.
8. If the fan blade speed was greater than specified, install a new fan clutch.

Fan Clutch Test - Maximum Speed Requirement

1. Use a suitable marker to mark the coolant pump or fan pulley and one of the fan blades.
2. Block off areas on each side of the radiator in the engine compartment, the front of the radiator grille and the bumper. Close the hood. This will raise the temperature of the air striking the fan clutch and should cause the fan blade to operate at maximum speed.
3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position, if equipped.
4. Start the engine and run it at approximately 2,000 RPM until normal operating temperature has been achieved. Using an infrared thermometer, monitor the coolant pump or fan pulley. Run the engine until the coolant pump or fan pulley is at least 96°C (205°F).
5. Aim a laser photo tachometer at the coolant pump or fan pulley. Run the engine to achieve 3,000 RPM at the coolant pump or fan pulley.
6. With the coolant pump or fan pulley at 3,000 RPM, aim the laser photo tachometer at the fan blade. Monitor and record fan blade speed.
7. The fan blade speed must be greater than the specified RPM at 3,000 RPM coolant pump or fan pulley RPM. Refer to the «SPECIFICATION TABLE»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) for correct fan speed.
8. Open the hood and allow the engine to idle momentarily to lower engine temperature. Turn the engine off and remove the blocks from the radiator, grille and bumper.
9. If the fan blade speed is less than specified, install a new fan clutch.

Cooling System Draining, Filling and Bleeding

SPECIAL TOOL(S) CHART RADKITPLUS 078-00497

Scheme 5

MATERIAL CHART

Draining

Note. The addition of Cooling System Stop Leak Pellets or equivalent meeting Ford specification WSS-M99B37-B6 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»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. 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.
3. Place a suitable container below the radiator draincock. Open the draincock and allow to drain. Close the draincock after draining.
4. When the coolant is drained, make sure drain plugs are installed and tight.

Filling and Bleeding with RADKITPLUS

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. The addition of Cooling System Stop Leak Pellets or equivalent meeting Ford specification WSS-M99B37-B6 darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

Scheme 6

Scheme 7

1. Open the degas bottle cap and the bleed valve on the back of the engine water outlet.
2. Open the degas bottle cap and the bleed valve on the upper radiator hose.
3. Fill the degas bottle to the MAX fill line.
4. Close the degas bottle cap and the bleed valve.
5. Start the engine and let it idle for 10 minutes or until the engine reaches normal operating temperature.
6. Allow the engine to cool and repeat Step 3 if necessary.
7. Start the engine and turn the heater to the MAX position.
8. Run the engine at 2,500 RPM for 10 minutes.
9. Repeat Step 8 if necessary.
10. Check the engine coolant level in degas bottle and fill as necessary.

Cooling System Flushing

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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) . 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. Remove the radiator. For additional information, refer to «RADIATOR»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
3. Backflush the radiator with the radiator in an upside-down position with a high-pressure hose in the lower hose location and backflush.
4. Remove the thermostat. For additional information, refer to «THERMOSTAT HOUSING - 2.3L»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__thermostat-housing-23l) or «THERMOSTAT HOUSING - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
5. Backflush the engine. Position the high-pressure water hose into the engine through the engine return and backflush the engine.

Block Heater

2.3L

Scheme 8

3.0L

Scheme 9

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
3. Disconnect the block heater electrical connector.
4. Remove the block heater. To install, tighten to 21 Nm (15 lb-ft).
5. Remove the block heater. To install, tighten to 41 Nm (30 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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Thermostat Housing - 2.3L

Note. The thermostat and thermostat housing are serviced as an assembly.

Scheme 10

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Thermostat - 3.0L

MATERIAL CHART

Scheme 11

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Scheme 12

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
3. Remove the air cleaner outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)»(/lincoln/zephyr/us-2006-2006/remont/removal-installation/#intake-air-distribution-filtering-30l-4v) .
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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Scheme 13

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
3. Remove the intake manifold. For additional information, refer to «ENGINE - 2.3L»(ref-256212) .
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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Bypass Tube - 3.0L

MATERIAL CHART

Scheme 14

Scheme 15

1. Remove the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING - 3.0L»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Coolant Pump - 2.3L

MATERIAL CHART

Scheme 16

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
3. Loosen the 3 coolant pump pulley bolts.
4. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE - 2.3L»(ref-256222) .
5. Remove the 3 bolts and the coolant pump pulley. To install, tighten to 20 Nm (15 lb-ft).
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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Coolant Pump - 3.0L

SPECIAL TOOL(S) CHART Service Set, Water Pump Pulley 303-S455 (T94P-6312-AH) Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Installer, Power Steering Pump Pulley (Nut only) 211-185 (T91P-3A733-A)

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

Scheme 22

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
3. Remove the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .
4. Using the special tool, remove the coolant pump drive 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. Using the special tool, install the coolant pump drive pulley.
5. Install the coolant pump belt. For additional information, refer to «ACCESSORY DRIVE - 3.0L (4V)»(ref-256223) .
6. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/lincoln/zephyr/us-2006-2006/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/lincoln/zephyr/us-2006-2006/remont/body-electrical/#battery-mounting-and-cables) .
3. Remove the generator air inlet duct.
4. If equipped, detach the 3 block heater wiring retainers from the cooling fan motor and shroud and position aside.
5. Remove the splash shield.
6. Detach the lower radiator hose bracket from the cooling fan motor and shroud.
7. Detach the retainer on the lower radiator hose from the cooling fan motor and shroud.
8. Detach the transmission cooler tubes from the cooling fan motor and shroud.
9. Detach the 4 wiring harness retainers and position the harness aside.
10. Disconnect the cooling fan electrical connector.
11. Release the 2 tabs and remove the cooling fan motor and shroud.
12. To install, reverse the removal procedure.

Scheme 29

Scheme 30

Scheme 31

Scheme 32

Scheme 33

Scheme 34

Scheme 35

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .
2. Remove the cooling fan motor and shroud. For additional information, refer to «COOLING FAN MOTOR AND SHROUD»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling) .
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 pushpin-type retainer.
11. Squeeze the tabs and separate the A/C condenser from the radiator and 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»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) .

Scheme 36

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 clamps pliers, clamp the lower degas bottle hose.
3. Using a suitable suction device, siphon the coolant from the degas bottle.
4. Disconnect the upper degas bottle hose and position aside.
5. Disconnect the lower degas bottle hose and position aside.
6. Remove the nut, bolt and the degas bottle. To install, tighten to 9 Nm (80 lb-in).
7. To install, reverse the removal procedure.
8. Fill the degas bottle. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/lincoln/zephyr/us-2006-2006/remont/cooling-system-mechanical/#engine-cooling__cooling-system-draining-filling-and-bleeding) for the recommended coolant mixture and fill level.

See also:
• ENGINE SYSTEM-GENERAL INFORMATION
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC CONTROL MODULES
• INSTRUMENT CLUSTER
• CLIMATE CONTROL SYSTEM-GENERAL INFORMATION AND DIAGNOSTICS
• JACKING & LIFTING
• INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V)
• BATTERY, MOUNTING AND CABLES
• ENGINE COOLING
• SYMPTOM CHART
• PINPOINT TEST B
• PINPOINT TEST C
• PINPOINT TEST A
• INSPECTION AND VERIFICATION
• CAP
• COOLING SYSTEM FLUSHING
• FAN CLUTCH TEST
• THERMOSTAT VISUAL INSPECTION
• GENERAL SPECIFICATIONS
• THERMOSTAT HOUSING - 2.3L
• COOLING SYSTEM DRAINING, FILLING AND BLEEDING