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Engine Cooling System: Maintenance Mercury Sable IV

Cooling Fan 69 illustrations ~1569 words

Draining

WARNINGNever remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. Failure to follow these instructions can result in personal injury.
CAUTIONThe coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be recycled or disposed of correctly.
CAUTIONSome vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC- 4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7- B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types.

Note. The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, 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.

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  1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half to one turn counterclockwise to the first stop on the filler neck. When the pressure has been released, remove the pressure relief cap.
  2. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  3. Remove the front splash shield.
  4. Place a suitable container below the radiator draincock. Drain the coolant.
  5. Close the radiator draincock when finished.

Cooling System Flushing

ItemSpecification
Premium Cooling System Flush F1AZ-19A503ESR-M14P7-A

MATERIAL SPECIFICATIONS

  1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  2. Remove the water thermostat (8575).
  3. Install the water hose connection (8592) without the water thermostat.
  4. Using a suitable coolant system flushing tool and premium flush, flush the engine and radiator.
  5. Install the water thermostat.
  6. Backflush the heater core (18476) if necessary.
  7. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .

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Scheme 30: Removal and Installation
Scheme 30: Removal and Installation
  1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  2. Raise the vehicle.
  3. Disconnect the block heater power cable from the block heater (6A051).
  4. Remove the block heater.
  5. To install, reverse the removal procedure.

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Scheme 31: Removal and Installation
Scheme 31: Removal and Installation

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  1. Partially drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  2. Remove the three thermostat housing bolts.
  3. Remove the thermostat O-ring seal. Inspect the sealing surfaces.
  4. To install, reverse the removal procedure.

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Scheme 33: Removal and Installation
Scheme 33: Removal and Installation

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  1. Raise and support vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  2. Remove the front splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-173840) .
  3. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  4. Remove the cooling tube bolt.
  5. Lower the vehicle.
  6. Remove the radiator upper cooling tube bolt.
  7. Disconnect the upper radiator hose and engine vent hose.
  8. Remove the two bolts, and separate the radiator tube from the thermostat housing. Remove the thermostat.
  9. To install, reverse the removal procedure.

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Scheme 37: Removal and Installation
Scheme 37: Removal and Installation

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  1. Raise and support vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  2. Remove the front splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-173840) .
  3. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  4. Remove the lower radiator hose, reservoir supply hose, and the radiator lower tube bolt.
  5. Lower the vehicle.
  6. Remove the radiator upper tube bolt, and disconnect the radiator vent tube.
  7. Disconnect the upper radiator hose and engine vent hose.
  8. Release the tabs on the power distribution box and position aside.
  9. Disconnect the oxygen sensor connector retainer and harness pin-type retainer.
  10. Remove the two bolts, and remove the radiator tube assembly.
  11. To install, reverse the removal procedure.

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Scheme 43: Removal and Installation
Scheme 43: Removal and Installation

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  1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  2. Remove the front splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-173840) .
  3. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  4. Lower the vehicle.
  5. Remove the air cleaner assembly.
  6. Remove the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-171833) .
  7. Disconnect the upper radiator hose and engine vent hose.
  8. Disconnect the transmission 10-pin connector.
  9. Remove the radiator bypass hose assembly.
  10. Disconnect the engine coolant temperature (ECT) sensor, water temperature sender, heater water hose and harness locator pin from the bypass tube.
  11. Remove the bolt and stud, remove water pump bypass tube. Inspect the O-rings. Install new if necessary.
  12. To install, reverse the removal procedure.

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Scheme 48: Removal
Scheme 48: Removal

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  1. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  2. Loosen the water pump pulley.
  3. Remove the accessory drive belt.
  4. Remove the degas bottle. For additional information, refer to «DEGAS BOTTLE»(ref-204655-S25135630512005111300000) .
  5. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-171833) .
  6. Disconnect the generator B+ cable and the voltage regulator electrical connector.
  7. Remove the nut, the bolt and the generator brace.
  8. Remove the generator mounting bolt and the generator.
  9. Remove the bolt and the nut, and position the roll restrictor bracket out of the way.
  10. Remove the bolt and the accessory drive belt tensioner.
  11. Remove the nut, the bolt and the support bracket.
  12. Remove the bolts and the water pump pulley.
  13. Disconnect the water pump inlet hose and the crankshaft position sensor electrical connector.
  14. Remove the bolts and the water pump, and clean the sealing surfaces.

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Scheme 58: Installation
Scheme 58: Installation

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Scheme 68
  1. Install the water pump. Tighten bolts in the sequence shown: Tighten numbers 1-7 to 25 N.m (18 lb-ft). Tighten numbers 8-12 to 10 N.m (89 lb-in).
  2. Connect the crankshaft position sensor electrical connector and the water pump inlet hose.
  3. Install the support bracket, the nut and the bolt.
  4. Install the accessory drive belt tensioner and the bolt.
  5. Install the water pump pulley and the bolts.
  6. Install the roll restrictor bracket, the bolt and the nut. Do not tighten at this time.
  7. Install the generator and the mounting bolt. Do not tighten at this time.
  8. Install the generator brace, the nut and the bolt.
  9. Tighten the generator lower mounting bolt.
  10. Tighten the roll restrictor bracket bolt and nut.
  11. Connect the generator electrical connectors. Connect the B+ cable. Connect the voltage regulator electrical connector.
  12. Install the accessory drive belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165359) .
  13. Install the degas bottle. For additional information, refer to «DEGAS BOTTLE»(ref-204655-S25135630512005111300000) .
  14. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-171833) .
  15. Fill the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .

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Scheme 69: Removal
Scheme 69: Removal

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  1. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  3. Remove the splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-173840) .
  4. Disconnect the heater water hose from the bottom of the water pump.
  5. Remove the radiator lower tube bolt.
  6. Lower the vehicle.
  7. Remove the air cleaner assembly.
  8. Remove the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-171833) .
  9. Remove the water pump belt. For additional information, refer to «DRIVE BELT ROUTING»(ref-139103-S33285511932002042500000) .
  10. Remove the radiator upper front tube bolt.
  11. Disconnect the upper radiator hose and engine vent hose.
  12. Disconnect the transmission 10-pin connector.
  13. Remove the radiator bypass hose assembly.
  14. Disconnect the thermostat housing and position aside.
  15. Remove the three bolts, and detach the water pump.
  16. Disconnect the connector hose, and remove the water pump.

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Scheme 78: Installation
Scheme 78: Installation

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  1. Connect the connector hose to the water pump.
  2. Position the water pump and install the mounting bolts. Tighten the bolts in two stages. Stage 1: Tighten to 10 N.m (89 lb-in). Stage 2: Tighten an additional 90 degrees.
  3. Connect the thermostat housing to the water pump hose.
  4. Install the radiator bypass hose assembly.
  5. Connect the transmission 10-pin connector.
  6. Connect the upper radiator hose and engine vent hose.
  7. Install the radiator upper front cooling tube bolt.
  8. Install the water pump belt. For additional information, refer to «SPECIFICATIONS & DRIVE BELT ROUTING»(ref-165359) .
  9. Install the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-171833) .
  10. Install the air cleaner assembly.
  11. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  12. Install the lower cooling tube bolt.
  13. Connect the heater water hose to the bottom of the water pump.
  14. Install the splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-173840) .
  15. Fill the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .

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Scheme 87: Radiator
Scheme 87: Radiator

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Scheme 88: Removal and Installation
Scheme 88: Removal and Installation

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  1. Remove the battery and battery tray. For additional information, refer to «BATTERY, MOUNTING & CABLES»(ref-171833) .
  2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204655-S39647902322005111300000) .
  3. Disconnect the upper radiator hose.
  4. Disconnect the degas return hose.
  5. Using the special tool, disconnect the upper transmission cooler line.
  6. Remove the two A/C condenser retaining bolts.
  7. Raise and support the vehicle. For additional information, refer to «JACKING & HOISTING»(ref-163228-S11857246952004062300000) .
  8. Remove the radiator support bracket bolts and the radiator support bracket.
  9. Disconnect the lower radiator hose.
  10. Disconnect the lower transmission cooler line.
  11. Remove the two bolts retaining the condenser to the radiator.
  12. Secure the A/C condenser.
  13. Remove the bolt retaining the P/S cooler to the radiator.
  14. Remove the nuts and the radiator support brackets.
  15. Remove the radiator from the vehicle.
  16. To install, reverse the removal procedure.

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