1986 Cooling System-Service

1986
27-01-4 Cooling System-Service
27-01-4

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.

^ Radiator filler leak. ^ Inspect radiator filler neck sealing surface for damage or foreign material.
^ Internal leakage. ^ Check engine oil and transmission oil dipsticks for signs of coolant. Check coolant for signs of transmission oil.

^ Check torque of head boils, tighten if necessary.

^ Disassemble engine as necessary -check for cracked intake manifold, blown head gaskets, leak at water crossover intake manifold gasket, warped head or block gasket 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 an service as required. Refer to Body, Chassis, Electrical Manual, Group 33.

^ 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) -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.
(False Reading). Refer to electrical section.

Revised 8/88 CQ1531-G

1986
27-01-7
Cooling System-Service 27-01-7

Maximum Speed Fan Drive Requirement Test
1. If the minimum speed fan drive requirement test was not performed, follow Steps 1 through 5 under minimum speed fan drive requirement test.
2. Block off areas on each side of the radiator core in the engine compartment and the front of the grille. This will raise the temperature of the air striking the clutch control unit and should cause the fan to operate at maximum speed.
3. Place the air conditioning selector (if equipped) to the maximum position and the blower switch to the high position.
4. Adjust the strobe light to 2000 rpm.
WARNING: TO AVOID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN HAS BEEN FIRST EXAMINED FOR POSSIBLE CRACKS AND SEPARATION.
5. Start the engine and adjust it until the water pump pulley is synchronized with the strobe light. This will be near the engine testing speed given in the specifications.
6. Synchronize the timing light with the marked fan to clutch attaching bolts.

7. The fan speed must meet or exceed the specified maximum fan test speed at 2000 water pump rpm.
8. If the fan speed was less than the specified fan test speed, check for proper parts usage. If the correct parts are used, replace the fan drive clutch. If the part(s) are not the correct ones, replace the part(s) and perform the test again.

CLEANING AND INSPECTION

Coolant Replacement

1. Bring engine to normal operating temperature and turn 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 radiator or cooling system cap under any conditions while 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 stream, 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. Open radiator petcock and remove the cylinder block drain plug(s) to drain the coolant system.

d. Disconnect overflow hose from radiator filler neck connection. Remove coolant recovery reservoir from fender apron and empty fluid. Revised 8/88

Flush reservoir with clean water, drain and reinstall reservoir and strap (if so equipped) and overflow hose and clamp to radiator filler neck.

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 Cooing System Fast Flush D6AZ- 19A503-A (ESR-M14P7-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 draincock 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-M97B44-A such as Ford Cooling System Fluid E2FZ-19549-A or equivalent. Freeze protection may also be checked by using either a Rotunda Optical AntiFreeze/ Battery Tester 072-00005 or equivalent or a Hydrometer. A 50/50 mix of coolant concentrate and water will provide approximately -37~C (-35~F) protection, and afford necessary anti-corrosion protection.

2.3L (Thunderbird/Cougar, LTD/Marquis, Mustang/Capri) - 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 5 cm (0 to 2 inches) below the filler neck seat.

2. Operate engine until thermostat opens and the radiator upper hose becomes hot.

3. Stop the engine and add coolant to the filler neck seat.

4. Install radiator cap.

5. Add a 50/50 mixture of coolant and water to the FULL HOT mark on the coolant reservoir, to provide adequate cooling system fill. Install reservoir cap, if so equipped.