Engine Cooling System: Other Mercury Monterey VIII

Cooling Fans

The cooling fans are controlled by 5 relays to provide 3 speeds. If DTC P0480, P0481 or P0482 are present, See INTRODUCTION - GASOLINE article for diagnosis.

In all speeds, voltage is supplied to a specific cooling fan relay, which energizes the cooling fan motors based on cooling system temperature input from the cylinder head temperature sensor.

Possible Causes

1. An open circuit 3850 (LG/VT), 1826 (YE/RD), 471 (OG/LG), 1205 (BK), 1823 (YE/BK), 1825 (LG/YE), 461 (OG), 3828 (OG/BK), 462 (VT), 1824 (LG/VT) or 1822 (LB)
2. A short to ground or short to voltage on circuit 3850 (LG/VT) or 1826 (YE/RD)
3. Cooling fan relay
4. Cooling fan motor
5. Cooling fan resistor

1. A short to voltage on circuit 1825 (LG/YE) or 1824 (LG/VT)
2. Cooling fan relay

1. A short to ground on circuit 471 (OG/LG), 461 (OG), 3828 (OG/BK) or 462 (VT)
2. Cooling fan relay

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 the Radiator/Heater Core Pressure Tester and the 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

A new 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 can 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 to the cylinder head temperature (CHT) sensor. 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 2 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 TEMPERATURE CHART 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 temperatures is not above 82°C (180°F) or the corresponding voltages shown on the chart, install a new thermostat.
6. If the thermostat opening temperatures and voltages are within the specified range, the thermostat is good and a new thermostat is not required. GO to «SYMPTOM CHART»(ref-234494-S01389277032006061000000) .

Cooling Fan Motor and Shroud

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 shroud assembly.

Material

RADKITPLUS MATERIAL SPECIFICATION

Filling and 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.

Filling and Bleeding without RADKITPLUS

1. Add Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) 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 VC-2 or equivalent meeting Ford specification WSS-M97B44-D or green colored Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) meeting Ford specification ESE-M97B44-A or equivalent. Mixing coolants may degrade the coolant's corrosion protection.
3. Do not add alcohol, methanol, brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
4. Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications. Use of such coolants may harm the engine and cooling system components.

Note. The addition of Cooling System Stop Leak Pellets VC-6 or equivalent meeting Ford specification WSS-M99B37-B6 darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

1. During the initial fill, fill the degas bottle to the top of the cold fill range.
2. Move the temperature blend selector to the full WARM position and the fan motor control to HIGH for the front and rear unit, if equipped.
3. Start the vehicle with the coolant pressure relief cap off and allow to idle until the thermostat is open.
4. Top off the coolant in the degas bottle to the top of the cold fill range. Install and tighten the coolant pressure relief cap.
5. Increase the engine rpms to 3,000 for 15 seconds, and then return to idle for one minute.
6. Repeat the previous step 4 times or until heat is coming from the rear unit while the vehicle is idling.
7. Allow the vehicle to cool and top off the coolant in the degas bottle to the cold fill range.

Heater Core Backflushing

HEATER CORE BACKFLUSHING MATERIAL SPECIFICATION

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-234494-S34432732002006061000000) .
2. Using an appropriate cooling system flusher, backflush the heater core. Use Premium Cooling System Flush.
3. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-234494-S34432732002006061000000) .

BLOCK HEATER MATERIAL SPECIFICATION

Scheme 22

BYPASS TUBE MATERIAL SPECIFICATION

Scheme 23

ENGINE LIFT BRACKET SET MATERIAL SPECIFICATION

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-234483) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-234494-S34432732002006061000000) .
3. Remove the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-234525) .
4. Remove the engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
5. Disconnect the lower radiator hose from the coolant inlet pipe.
6. Remove the coolant pump inlet pipe bolt and the coolant pump inlet pipe.
7. Remove and discard the coolant pump inlet pipe O-ring seal.
8. Remove the bolt and the idler pulley. To install, tighten to 47 Nm (35 lb-ft).
9. Remove the 2 RH generator bracket brace bolts. To install, tighten to 25 Nm (18 lb-ft).
10. Remove the 2 LH generator bracket brace bolts and the generator bracket brace. To install, tighten to 47 Nm (35 lb-ft).
11. Install the special tools to the exhaust manifold.
12. Attach the engine lifting equipment and raise the engine 127 mm (5 in).
13. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.
14. Disconnect the coolant pump bypass hose from the bypass tube.
15. Remove the 2 coolant pump outlet tube bolts and the coolant pump outlet tube.
16. Remove and discard the coolant pump outlet tube O-ring seal.
17. Remove the 5 coolant pump-to-engine front cover nuts.
18. Remove the 4 coolant pump-to-engine front cover bolts.
19. Remove the coolant pump. Discard the coolant pump gasket.

Scheme 29

1. Position the coolant pump to the engine. Install a new coolant pump gasket.
2. Install the coolant pump-to-engine front cover bolts.
3. Install the coolant pump-to-engine front cover nuts.
4. Tighten the coolant pump-to-engine front cover nuts and bolts to 28 Nm (21 lb-ft). Tighten in the sequence shown.
5. Install the coolant pump outlet tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant.
6. Install the coolant pump outlet tube and the 2 coolant pump outlet tube bolts. Tighten to 10 Nm (89 lb-in).
7. Connect the coolant pump bypass hose to the bypass tube.
8. Install the coolant pump pulley and the 4 coolant pump pulley bolts. Tighten to 11 Nm (8 lb-ft).
9. Install the generator brace and the 2 LH generator bracket brace bolts. Tighten to 47 Nm (35 lb-ft).
10. Install the 2 RH generator bracket brace bolts. Tighten to 25 Nm (18 lb-ft).
11. Install the idler pulley and the bolt. Tighten to 47 Nm (35 lb-ft).
12. Install a new coolant pump inlet pipe O-ring seal. Lubricate the O-ring seal with clean engine coolant.
13. Install the coolant pump inlet pipe and the coolant pump inlet pipe bolt. Tighten to 25 Nm (18 lb-ft).
14. Connect the lower radiator hose to the coolant inlet pipe.
15. Lower the engine and install the engine mount nuts. To install, tighten to 90 Nm (66 lb-ft).
16. Install the accessory drive belt. For additional information, refer to «ACCESSORY DRIVE»(ref-234525) .
17. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-234494-S34432732002006061000000) .

Scheme 30

Scheme 31

1. For additional information, refer to the following procedures.

RADIATOR MATERIAL SPECIFICATION

Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-234483) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-234494-S34432732002006061000000) .
3. Remove the 8 pin-type retainers and the upper radiator sight shield.
4. Disconnect the cooling fan electrical connectors.
5. Disconnect the harness retainers from the fan shroud. To install, tighten to 10 Nm (89 lb-in).
6. Disconnect the upper radiator hose.
7. Remove the radiator alignment pins. Using mechanic's wire, tie the radiator and the condenser to the upper radiator support separately. Allow 2 inches of slack in the condenser wire to allow for movement. Remove the radiator alignment pins.
8. Disconnect the radiator vent hose from the radiator.
9. Disconnect the degas bottle return hose.
10. Disconnect the lower radiator hose.
11. Detach the transmission cooler tube clips.
12. Disconnect the transmission cooler tubes. Disconnect the fluid cooler tubes from the connector assembly. Push the fluid cooler tube inward slightly, squeeze the retaining clip, and with a slight twisting motion, pull the fluid cooler tube out of the connector.
13. Detach the transmission cooler tube pin-type retainers.
14. Detach the power steering tubes from both sides of the radiator lower support.
15. Remove the bolt and reposition the A/C muffler bracket aside. To install, tighten to 8 Nm (71 lb-in).
16. Remove the screws.
17. Remove the bolts and position the cooler aside. To install, tighten to 8 Nm (71 lb-in).
18. Remove the 4 bolts and the lower radiator support and insulators. To install, tighten to 25 Nm (18 lb-ft).
19. Remove the 2 radiator-to-condenser bolts. To install, tighten to 10 Nm (89 lb-in).
20. Remove the radiator. Lower the vehicle, cut the mechanic's wire on the radiator and remove the radiator, cooling fans and shroud as an assembly.
21. To install, reverse the removal procedure.
22. Fill the transaxle using clean automatic transmission fluid.
23. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-234494-S34432732002006061000000) .