Supplement # 2 - Attachment III

AFFECTED VEHICLES:
1996-1997 TAURUS EQUIPPED WITH 3.OL VULCAN METHANOL ENGINES VIN 8TH DIGIT = "1"

RECOMMENDED SUPPLIES -- FLUSH PROCEDURE





The components shown are referenced throughout the technical instructions to facilitate the flush procedures. The picture representation and sizes are provided for your reference. For additional or replacement items, procure locally as required.

INSPECTION





1. Check for presence of coolant by-pass hose shown in Figure 2, then proceed to Service Procedure.

SERVICE PROCEDURE

1. Raise and support the vehicle.

2. Remove the splash shield.

3. Lower the vehicle.

4. Remove the radiator draincock, then completely drain and discard cooling system fluid.

5. Loosen the water pump pulley retaining bolts. Do not remove the bolts at this time.





6. Remove the drive belt. Refer to Figure 3.

7. Remove the idler pulley. Refer to Figure 3.

8. Remove the drive belt tensioner. See Figure 3.

9. Remove the water pump pulley.





10. Remove the alternator brace lower retainer, then loosen the upper retainer. Swing the brace up and away from the water pump. See Figure 4.





11. Remove the A/C compressor brace upper retainer, then loosen the lower retainer. Swing the brace away from the water pump. Refer to Figure 5.

12. Remove the power steering line support bracket retainer, then position the bracket away from the water pump. See Figure 5.

13. Disconnect the heater return hose from the water pump and heater core return tube. Remove the heater return hose from the vehicle and discard both clamps.

14. Position the drain pan under the water pump.

15. Remove the water pump from the vehicle.

16. CAUTION:
Use care when scraping as aluminum gouges easily which may form leak paths. Clean the water pump gasket surface.

17. NOTE:
Lightly oil all bolt and stud bolt threads before installation. Using new gasket (-8507-), install the new water pump (F8DZ-8501-AA).





18. Tighten the water pump retaining bolts, shown in Figure 6, as follows:

^ Bolts 4, 5, 6, 7, 8 and 9 to 20-30 Nm (15-22 lb-ft).

^ Bolts 11, 12, 13, 14 and 15 to 8-12 Nm (71-106 lb-in).

19. Reposition the power steering line support bracket. Tighten the retainer to 23-32 Nm (17-24 lb-ft).

20. Reposition the A/C compressor brace. Tighten the retainers to 20-30 Nm (15-22 lb-ft).

21. Install the water pump pulley. Hand tighten the retaining bolts at this time.

22. Install the drive belt tensioner. Tighten the retainer to 40-55 Nm (30-40 lb-ft).

23. Install the idler pulley. Tighten the retainer to 68-92 Nm (50-68 lb-ft).

24. Install the drive belt.

25. Tighten the water pump pulley bolts to 20-30 Nm (15-22 lb-ft).

26. Remove the clean air tube.





27. Remove the cowl top inner panel drain tube. See Figure 7.





28. Remove the coolant recovery hose from fitting shown in Figure 8 and discard the clamp.

29. NOTE:
If the heater hose and tube assembly was previously installed, visually verify the presence of a restrictor in the coolant recovery fitting.

^ If the restrictor is present, the restrictor supplied in the kit is not required; proceed to Step 30.








^ If the restrictor is not present, use a suitable driver, represented in Figure 9, to install the restrictor insert (-8N030-) as shown in Figure 10. The restrictor insert must be installed flush to the shoulder on the coolant recovery fitting. It is acceptable if the restrictor insert is loose in the fitting.

30. Install the new screw clamp (376240-S100) on the coolant recovery hose. Reinstall the coolant recovery hose and tighten the clamp.





31. Remove the heater hose from the lower intake manifold fitting. See Figure 11.





32. Remove the two (2) heater hoses from the heater core. See Figure 12.

33. Remove the two (2) heater hose and tube assembly retaining nuts at the dash panel.

34. Remove and discard the heater hose and tube assembly.





35. NOTE:
Check the heater hose and tube assembly for possible kinks or possible interference with the transmission dipstick and ETA check valve. Install the new heater hose and tube (assembly includes the coolant by-pass hose) assembly (-18C533-) against the dash panel. Tighten the retaining screws to 8-10 Nm (6-7 lb-ft). See Figure 13.





36. NOTE:
The heater return hose has two different size ends. Use the 5/8" end for this step. Install the new screw clamp (389772-S100) on the heater return hose. Install the hose on the new tube assembly, and tighten the clamp. See Figure 14.

37. Connect the heater hoses to the heater core and secure the clamps inside of the "H" markings.

38. Install the new heater hose to the lower intake manifold heater supply fitting and install the clamp inside the "H" marking. Make sure that the "H" marking on the hose is in the straight-up position.

39. Reinstall the cowl top inner drain tube.

40. Reinstall the clean air tube.

41. Disconnect the upper radiator hose from the thermostat housing and discard the clamp.





42. Using clamping pliers, clamp off the coolant by-pass hose at the center of hose. See Figure 15.

43. Raise and support the vehicle.

44. Remove the engine block core plug located next to the oil filter. On the opposite side of the engine block, there are two core plugs; remove the engine block core plug closest to the water pump.

45. Remove the lower radiator support bracket that covers the lower radiator hose.

46. Remove the lower radiator hose from the radiator and discard the clamp.

47. Clean core plug bores in the cylinder block with a sand paper drum (Fine 150-grit 1.5" dia.). Make sure all Loctite(R) and rust is removed from the core plug bore.

48. Lower the vehicle.

49. Push the vehicle to a flushing station.





50. Connect a garden hose to the heater return hose using an adapter. See Figure 16.

51. Turn the garden hose on full pressure.

52. Flush the engine/heater core for ten (10) minutes. Water will drain out of the core plug holes.

53. Disconnect the garden hose from the heater return hose.





54. Insert the garden hose into the upper radiator hose. See Figure 17.

55. Flush the radiator for two (2) minutes. Water will drain out of the lower radiator hose connection and draincock.

56. Remove the garden hose from the upper radiator hose.





57. Insert the garden hose into the coolant recovery bottle. See Figure 18.

58. Flush the coolant recovery bottle for four (4) minutes. Water will drain out of the lower radiator hose.

59. Remove the garden hose from the coolant recovery bottle. Let the cooling system completely drain before proceeding to the next step.

60. Push the vehicle back to the hoist.

61. Raise and support the vehicle.

62. Lubricate 0-rings of the new engine core plugs (-6C057-) with Silicone Dielectric Grease (WA-10).





63. Install left and right bank front engine core plugs. Index the dimples on the plugs to the 12 o'clock position. Refer to Figure 19.

64. NOTE:
Do not over tighten. Tighten core plug retaining nuts to 3.2 Nm (28 lb/in). See Figure 19. Use of a 1/4" drive, 8 mm flex socket with a long extension is acceptable. Make sure plugs do not rotate when tightening the retaining nut.

65. Install the new screw clamp (383525-S) on the lower radiator hose. Connect the lower radiator hose to the radiator and tighten the clamp.

66. Install the lower radiator support bracket.

67. Install and tighten the radiator draincock.

68. Lower the vehicle.

69. Turn the heater and blower switches to the OFF position.

70. Remove clamping pliers from the coolant by-pass hose.

71. Install the new screw clamp (383525-S) on the upper radiator hose. Connect the upper radiator hose to the thermostat housing and tighten the clamp.





72. WARNING:
WEAR RUBBER GLOVES DURING THIS STEP. THE CHEMICAL CLEANER USED MAY CAUSE SKIN IRRITATION. DO NOT add chemical cleaner to the coolant recovery bottle. Using a funnel, slowly add one (1) bottle of chemical cleaner (-19A503-) into the HEATER RETURN HOSE. See Figure 20.

73. Install the new screw clamp (388788-S), reconnect the heater return hose to water pump fitting and tighten the clamp.

74. Slowly fill cooling system with water. Squeeze the upper radiator hose to purge air from the system as water is added. Coolant level must be filled to the top of the clear portion of the coolant recovery bottle to completely clean the coolant recovery bottle.

75. Start the engine and rev to 2000 RPM for one (1) minute. Do not exceed 2500 RPM.

76. Check the cooling system for leaks.

77. Recheck the coolant level. Using water, bring level to the top of the clear portion of the coolant recovery bottle, if necessary.

78. Install the coolant pressure relief cap.

79. Run the engine at idle until the upper radiator hose is hot (when thermostat opens) approximately 12 minutes.

80. Turn the engine off and let chemical solution soak for a minimum of thirty (30) minutes, while the engine cools.

81. WARNING:
COOLANT MAY BE HOT. Remove the coolant pressure relief cap.

82. Partially raise the vehicle.

83. WARNING:
WEAR RUBBER GLOVES DURING THIS STEP. THE CHEMICAL CLEANER USED MAY CAUSE SKIN IRRITATION. Remove the radiator draincock.

84. Completely drain the chemical solution from the cooling system and discard.

85. Lower the vehicle.

86. Loosen the screw clamp and disconnect the heater return hose from the water pump fitting.





87. Install a 3/4" I.D. rubber cap on the water pump heater hose fitting. See Figure 21.





88. Disconnect and plug the radiator overflow hose from the coolant recovery bottle. Discard the clamp. Refer to Figure 22.

89. Install the coolant pressure relief cap.

90. Attach a 4-foot section of 3/8-inch vinyl hose to the overflow fitting on the coolant recovery bottle. See Figure 22. Let the vinyl hose hang over the fender.

91. Push the vehicle to a flushing station.

92. Connect the garden hose to the heater return hose using an adapter.

93. Turn the garden hose on full pressure.

94. With the engine off, flush engine for five (5) minutes. Water will drain out of the radiator draincock hole and 4 ft. hose attached to the coolant recovery bottle.

95. Turn the garden hose off and remove the coolant pressure relief cap from the coolant recovery bottle.

96. Disconnect the garden hose from the heater hose. Let the cooling system completely drain before proceeding to the next step.

97. Push the vehicle back to the hoist.

98. Raise and support the vehicle.

99. Install and tighten the radiator draincock.

100. Install the splash shield.

101. Lower the vehicle.

102. Remove the rubber cap from the water pump heater hose fitting.

103. Reconnect the heater return hose to the water pump and tighten the clamp.

104. Reattach and secure the alternator brace.

105. Remove the 3/8-inch vinyl hose from the coolant recovery bottle.

106. Unplug the radiator overflow hose, then install the new screw clamp (376240-S100). Reconnect the radiator overflow hose to the coolant recovery bottle and tighten the clamp.

107. Add one (1) bottle (16 oz.) of Heavy Duty Cooling System Additive (FW-16) to the coolant recovery bottle.

108. Add 6 quarts of new coolant (-19549-) to the coolant recovery bottle. Fill remainder of cooling system with water to cold fill line on the coolant recovery bottle.

109. Start the engine and top off with water to cold fill line, if necessary.

110. NOTE:
This step must be done before the thermostat opens. Rev the engine to 3000 RPM for 30 seconds, and check for foaming inside coolant recovery bottle. If foaming is present, turn off the engine and refer to Coolant By-Pass Restrictor installation procedure, as the coolant by-pass restrictor has not been installed.

111. Install the coolant pressure relief cap.

112. Select maximum heater temperature and blower motor speed settings. Position the control to discharge air at the panel vent in instrument panel.

113. Start the engine and allow to idle until normal operating temperature is reached. While the engine is idling, feel for hot air at panel vents.

114. CAUTION:
If air discharge remains cool and engine coolant temperature gauge does not move, engine coolant level is low and must be filled. Stop the engine, allow to cool and fill the cooling system as described. Start the engine and allow to idle until normal operating temperature is reached. Hot air should discharge from the panel vents. The engine coolant temperature gauge should maintain a stabilized reading to within NORMAL range and the upper radiator hose should feel hot to the touch.

115. Shut the engine off and allow to cool.

116. Check the engine for coolant leaks.