1983 Cooling System-General Service
1983
27-01-2 Cooling System-General Service 27-01-2
CONDITION POSSIBLE SOURCE ACTION
Loss of coolant ^ Pressure cap and gasket. ^ Inspect, wash gasket and test. Replace only if cap will not hold pressure test specification.
^ Leakage ^ Pressure test system.
^ External Leakage ^ Inspect hose, hose connection, radiator, edges of cooling system gaskets, core plugs and drain plugs, transmission oil cooler lines, water pump, heater system components. Service or replace as required.
^ Check engine oil and transmission oil dipsticks for signs of coolant. Check coolant for signs of transmission oil.
^ Check torque of head bolts, tighten if necessary.
^ Internal Leakage. ^ Disassemble engine as necessary - check for cracked intake manifold, blown head gaskets, warped head or block gaskets surfaces, cracked cylinder head or engine block.
Engine overheats ^ Low coolant level. ^ Fill as required. Check for coolant loss.
^ Excessive rust in coolant ^ Flush system, refill with new coolant.
^ Loose fan belt ^ Adjust.
^ Pressure cap. ^ Test. Replace if necessary.
^ Radiator or A C condenser ^ Remove bugs. leaves, etc.
obstruction.
^ Closed thermostat. ^ Test, replace if necessary.
^ Fan drive clutch ^ Test, replace if necessary.
^ Ignition ^ Check timing and advance. Adjust as required.
^ Temp gauge or cold light. ^ Check electrical circuits and service as required. Refer to Volume 3.
^ Engine ^ Check water pump block for blockage
^ 2.3L (Thunderbird/Cougar, ^ Check for air pockets trapped in cooling system (see coolant refill procedure) LTD/Marquis, Mustang/Capri,
Fairmont Futura/Zephyr) - only
^ Exhaust system ^ Check for restrictions.
Engine fails to reach normal ^ Open thermostat ^ ^ Test, replace if necessary.
operating temperature
^ Temperature gauge or cold light ^ Check electrical circuits and service as required. Refer to
(False Reading) electrical section.
Revised 8/88 CQ1531-D
1983
27-01-7 Cooling System-General Service 27-01-7
Removal
1. Drain the cooling system so that the coolant level is below the thermostat.
2. Disconnect the heater return hose at the thermostat housing located on the left front lower side of engine.
3. Remove the coolant outlet housing retaining bolts. Pull the housing away from the cylinder head or manifold sufficiently to provide access to the thermostat. Remove the thermostat by rotating counterclockwise in the housing until the thermostat becomes free to remove (do not pry). Remove the gasket.
FIGURE 3 - THERMOSTAT INSTALLATION 2.3L ENGINES:
Installation
Check the thermostat before installing it, following the Thermostat Test. Clean the coolant outlet housing and cylinder head, manifold or water pump gasket surfaces. Coat a new gasket with water resistant sealer B5A-19554-A or equivalent. Position the gasket on the cylinder head opening. The gasket must be positioned on the cylinder head or the intake manifold, before the thermostat is installed. To prevent incorrect installation of the thermostat, the water outlet casting on all engines contain a locking recess into which the thermostat is turned and locked. Install the thermostat with the bridge section (Fig. 3) in the outlet casting. Turn the thermostat clockwise to lock it in position on the flats cast into the outlet elbow.
On a vehicle equipped with a 2.3L engine, it is imperative that the correct thermostat installation alignment be made to provide coolant flow to heater. Insert and rotate thermostat assembly to the left or right until it stops in the water outlet housing - then visually check for full width of heater outlet tube opening to be visible within the thermostat port in assembly, (Fig. 3). This port alignment at assembly is required to provide maximum coolant flow to the heater.
2. Position the coolant outlet elbow against the cylinder head, intake manifold or water pump. Install and tighten the retaining bolts to specifications.
3. Connect heater hose to thermostat housing.
4. Fill the cooling system with the recommended permanent antifreeze, 8A-19549-A or equivalent Revised 8/88
and water mixture. If equipped with a crossflow radiator, follow the special instructions in Section 27-03 regarding checking coolant level. Check for leaks and proper coolant level after the engine has reached normal operating temperatures.
CLEANING AND INSPECTION
Coolant Replacement
1. Bring the engine to normal operating temperature and turn the engine Off. With cooling system under pressure, inspect cooling system hoses and clamped hose connections for leaks, excessive deterioration, or contact wear. Inspect radiator installation retention. Note any discrepancies, and proceed.
2. Drain coolant as follows:
a. Never remove the radiator or cooling system cap under any conditions while the engine is operating. Failure to follow these instructions could result in personal injury and/or damage to the cooling system or engine.
b. To avoid burns from scalding coolant or steam, use extreme care when removing the radiator cap. Switch the engine Off and wait until cool, then if radiator is still hot, carefully wrap a thick cloth around the cap and rotate slowly to the first stop. Step back until the pressure is released then press down on the cap and rotate until free. Remove the cap.
c. Place the heater temperature control at the maximum heat position.
d. Open radiator petcock and remove the cylinder block drain plug(s) to drain the coolant system.
e. Correct/service/replace any components found to be discrepant in Step 1.
Cleaning
To remove rust, sludge and other foreign material from the cooling system, use an appropriate cooling system flush such as Ford Radiator Flush, D6AZ-19A503-A or equivalent. Removal of such material restores cooling efficiency and avoids overheating. Always remove the thermostat prior to pressure flushing. A pulsating or reversed direction of flushing water flow will loosen sediment more quickly than a steady flow in the normal direction of coolant flow. In severe cases where cleaning solvents will not properly clean the cooling system for efficient operation, it will be necessary to use the pressure flushing method. Various types of flushing equipment are available.
Coolant Refill
1. Refill engine cooling system as follows:
a. Close radiator petcock and install cylinder block drain plug(s).
b. When refilling the cooling system, use equal parts of water and coolant as follows:
Coolant Specification: Use only a permanenttype coolant that meets Ford Specification ESE-M97B18-C (EIFZ-19549-A) or equivalent. (In 3.8L engines use ESE-M97B43-A Prestone 11.) Do not use alcohol or methanol antifreeze or mix them with the specified coolant.
1983
27-01-8 Cooling System - General Service
27-01-8
Freeze protection may also be checked by using either a Rotunda optical antifreeze/ battery tester or a Hydrometer. A 50/50 mix of coolant concentrate and water will provide approximately -35~F protection, and afford necessary anti-corrosion protection.
2.3L (Thunderbird/cougar, LTD/Marquis, Mustang/Capri, Fairmont Futura/Zephyr) -only
c. Disconnect heater hose at the water outlet connection on the thermostat housing.
d. Fill radiator until coolant is visible at the connection in the thermostat housing or the coolant level in the radiator reaches the radiator cap filler neck seat.
e. Install heater hose and tighten hose clamps to 1.36-2.03 N-m (12-18 lbs.in.)
Refill the radiator to approximately 0 to 2 inches below the filler neck seat on a crossflow radiator (horizontal tubes) and to approximately 3/4-inch below the filler neck seat on a downflow radiator (vertical tubes) with the recommended coolant mixture.
2. Operate engine until thermostat opens and the radiator upper hose becomes hot.
3. Stop the engine and add coolant to approximately 1-1/2 inches below the filler neck seat on a crossflow radiator, and to approximately 1/4-inch below the filler neck seat on a downflow radiator. Do not add coolant to expansion bottle (no filler neck) if so equipped.
4. Reinstall radiator or cooling system cap.
Heater Core Back-Flushing
All engine cooling system flushing and back-flushing procedures must include a separate back-flushing of the heater or A/C system heater core, after the flushing or back-flushing of the engine cooling system, to prevent engine cooling system particles from clogging the heater core tubes and reducing (or eliminating) coolant flow through the heater core. The heater core must be back-flushed separately from the engine cooling system for proper back-flush water flow direction through the heater core.
The correct heater core back-flushing procedure is as follows:
1. Disconnect the heater core outlet heater hose from the water pump fitting and install a female garden hose-end fitting adapter in the end of the outlet heater hose. Secure with a hose clamp.
2. Connect the female garden hose end of the outlet heater hose to the male end of a water supply garden hose.
3. Disconnect the heater core inlet heater hose from the engine block fitting and allow to drain onto the ground or into a floor drain.
4. If a water valve is installed in the heater core inlet heater hose, check to be certain the water valve is open (no vacuum).
5. Turn the water supply valve On and Off several times so that the surge action will help to dislodge larger stubborn particles from the heater core tubes. Allow full water pressure to flow for approximately five minutes.
6. If a water valve is installed in the heater core inlet heater hose, apply vacuum to the water valve vacuum motor to assure proper operation of the water valve and proper closure with no water leakage. Replace the water valve if required.
7. Remove the hose clamp and female garden hoseend adapter from the end of the outlet heater hose and reconnect the outlet heater hose onto the water pump fitting.
8. Reconnect the inlet heater hose onto the engine block fitting.
9. Fill the cooling system, as described in Section 27-03 using the specified, coolant mixture.
10. Test the system for proper heater performance with the specified engine cooling system conditions.
FIGURE 4 - RADIATOR CAP AND FILLER NECK OPENINGCLEANING AND INSPECTING-TYPICAL:
Radiator Pressure Cap
1. Inspect the areas under the vacuum valve and rubber seal for rust or dirt particles (Fig. 4).
2. Use warm tap water, raise the vacuum valve and rubber seal and thoroughly flush away loose rust or dirt particles trapped under the vacuum valve, rubber seal and on the seal surface.
3. Inspect and remove any imbedded rust or dirt particles on the sealing surfaces of the rubber seal.
4. Inspect the radiator filler neck opening for rust or dirt particles on the sealing surface at the bottom of the filler neck opening. Use a clean cloth and wipe the sealing surface to remove any rust or dirt particles.
NOTE: If paint is observed on the filler neck sealing surface, remove it using paint thinner.