Engine Cooling System: Removal & Installation Mercury Montego III

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-232992) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
3. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .
4. Disconnect the block heater electrical connector and position aside.
5. Remove the block heater. To install, tighten to 21 Nm (15 lb-ft).
6. To install, reverse the removal procedure.
7. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .

Scheme 1

Scheme 2

1. For additional information, refer to the «PROCEDURES»(ref-233003-S39061884802006052400000) .

Removal

1. Remove the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING»(ref-233003-S33225267642006052400000) and «THERMOSTAT AND THERMOSTAT HOUSING - EXPLODED VIEW»(ref-233003-S35842524092006052400000) .
2. Remove the 3 thermostat housing bolts and separate the upper and lower thermostat housing.
3. Remove the thermostat. Remove the O-ring seal and discard. Remove the thermostat.

Installation

1. Align the thermostat bridge with the alignment marks and install it in the upper housing.
2. Lubricate a new O-ring seal with clean engine coolant and install it in the upper housing.
3. Install the lower thermostat housing and the 3 bolts. Tighten to 10 Nm (89 lb-in).
4. Install the thermostat housing. For additional information, refer to «THERMOSTAT AND THERMOSTAT HOUSING - EXPLODED VIEW»(ref-233003-S35842524092006052400000) and «THERMOSTAT HOUSING»(ref-233003-S33225267642006052400000) .
5. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
3. Disconnect the degas bottle-to-thermostat housing hose and position aside.
4. Disconnect the throttle body-to-thermostat housing hose and position aside.
5. Disconnect the upper radiator-to-thermostat housing hose and position aside.
6. Disconnect the bypass tube-to-thermostat housing hose and position aside.
7. Disconnect the heater hose from the thermostat housing and position aside.
8. Disconnect the lower radiator-to-thermostat housing hose and position aside.
9. Remove the 2 bolts and the thermostat housing. Discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
10. To install, reverse the removal procedure. Install a new O-ring on the thermostat housing and lubricate with clean engine coolant.
11. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .

Scheme 3

Scheme 4

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
3. Disconnect the thermostat housing-to-bypass tube hose and position aside.
4. Remove the 2 thermostat housing bolts and position aside the thermostat housing. Discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
5. Remove the 4 roll restrictor bracket bolts and the roll restrictor bracket. To install, tighten to 55 Nm (40 lb-ft).
6. Disconnect the bypass tube hose and position aside.
7. Disconnect the bypass tube electrical connector.
8. Remove the 2 bolts and the coolant bypass tube. Remove and discard the O-ring seal and gasket. To install, tighten to 10 Nm (89 lb-in).
9. To install, reverse the removal procedure.
10. Clean the sealing surfaces and install a new gasket and O-ring seals.
11. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
3. Disconnect the thermostat housing-to-bypass tube hose and position aside. To install, tighten to 5 Nm (44 lb-in).
4. Remove the 2 thermostat housing bolts and position aside the thermostat housing. Discard the O-ring seal. To install, tighten to 10 Nm (89 lb-in).
5. Disconnect the coolant pump hose and position aside.
6. Remove the 4 coolant pump bolts and the coolant pump. To install, tighten in the following sequence: Tighten the coolant pump center bolt to 4 Nm (35 lb-in). Loosely install the 3 coolant pump outer bolts. Tighten the coolant pump center bolt to 25 Nm (18 lb-ft). Tighten the 3 coolant pump outer bolts to 10 Nm (89 lb-in).
7. To install, reverse the removal procedure. Install a new sealing washer on the center coolant pump bolt. Install a new O-ring seal on the thermostat housing and lubricate with clean engine coolant.
8. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .

Scheme 5

Scheme 6

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .
2. Remove the air cleaner assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-233002) .
3. Remove the cooling fan motor and shroud. For additional information, refer to «COOLING FAN MOTOR AND SHROUD»(ref-233003-S36500598152006052400000) .
4. Remove the front grille. For additional information, refer to «EXTERIOR TRIM AND ORNAMENTATION»(ref-233040) .
5. Disconnect the upper radiator hose and position aside.
6. Disconnect the lower radiator hose and position aside.
7. Disconnect the horn assembly electrical connector.
8. Remove the horn assembly bolt and the horn assembly. To install, tighten to 10 Nm (89 lb-in).
9. Remove the 2 A/C condenser retaining bolts and position aside the A/C condenser. To install, tighten to 6 Nm (53 lb-in).
10. Remove the 2 radiator support bracket bolts. To install, tighten to 6 Nm (53 lb-in).
11. Remove the 2 radiator support brackets and position the radiator forward.
12. Remove the transmission cooler bracket bolt. To install, tighten to 6 Nm (53 lb-in).
13. Lift the transmission cooler off the retainers and position aside.
14. Remove the radiator.
15. To install, reverse the removal procedure.
16. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .

Scheme 7

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-233036) .
2. Disconnect the 2 coolant hose retainers from the fan shroud and position aside.
3. Disconnect the cooling fan motor electrical connector.
4. Remove the 2 cooling fan motor and shroud bolts and release the cooling fan motor and shroud from the lower brackets. To install, tighten to 6 Nm (53 lb-in).
5. To install, reverse the removal procedure.

Scheme 8

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .
2. Disconnect the upper degas bottle hose and position aside.
3. Disconnect the lower degas bottle hose and position aside.
4. Remove the 2 degas bottle bolts and position aside to access the electrical connector. To install, tighten to 9 Nm (80 lb-in).
5. Disconnect the degas bottle electrical connector and remove the degas bottle.
6. To install, reverse the removal procedure.
7. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-233003-S08782495312006052400000) .