Service Procedure
WARNINGIF ENGINE BLOCK HEATER HAS SEPARATED FROM THE CYLINDER BLOCK, VERIFY ENGINE DAMAGE HAS NOT OCCURRED DUE TO OVERHEATING. IF ENGINE DAMAGE IS EVIDENT, PERFORM NECESSARY REPAIRS BY REFERRING TO THE APPROPRIATE SERVICE MANUAL. IF ENGINE HAS NOT OVERHEATED OR COOLANT LEAK WAS MINOR, REPLACE THE ENGINE BLOCK HEATER USING THE FOLLOWING PROCEDURE.
1. When engine is cold, relieve radiator pressure and remove cap. Drain cooling system.
2. Disconnect negative battery cable.
3. Disconnect the block heater power cable from the block heater (Figure 1, View A).
4. Loosen the screw on the block heater (8 mm) and back the screw out slowly until a slight resistance is felt (Figure 1, View B).
5. Pry the block heater from the cylinder block. Remove the heater by tipping the heater and guiding the block heater inner crossbar out of the cylinder block hole. Pry the crossbar with a screwdriver to aid removal (Figure 1, View C).
CAUTION
USE EXTREME CARE TO PREVENT SCRATCHING THE CYLINDER BLOCK BORE, AS THIS WILL RESULT IN COOLANT LEAKS.
NOTE
DISCARD ANY BLOCK HEATER WHICH HAS BEEN PREVIOUSLY INSTALLED. REINSTALLING A BLOCK HEATER WILL RESULT IN COOLANT LEAKS.
6. Clean the inside diameter of the cylinder block hole machined surface and hole entrance with a rag. Check the machined surface of the hole to be sure it is free of nicks, scratches, and porosity. If porosity is found, please contact the Ford Chihuahua Engine Plant Hotline: from the US, call (800) 252-0951 8AM-8PM Eastern Time; from outside the US, call 52-14-29-4216 or fax 52-14-29-4211.
7. Apply a liberal amount of Premium Engine Coolant (E2FZ-19549-AA; in Oregon, F5FZ-19549-CC; in Canada, CXC-1O), meeting Ford specification ESE-M97B44-A or equivalent, to the 0-ring on the revised Engine Block Heater (F5RZ-6A051-AA) and cylinder block bore.
NOTE
NEVER USE RTV OR ANY TYPE OF SEALER ON THE BLOCK HEATER O-RING OR CYLINDER BLOCK BORE. THIS WILL RESULT IN COOLANT LEAKS.
8. Install the revised engine block heater into the cylinder block bore with the power cable connector at the 3 o'clock position (Figure 1, View D). Fully seat the heater into the block.
CAUTION
DO NOT OVER TORQUE BLOCK HEATER SCREW. THIS WILL DISTORT THE BLOCK HEATER BODY AND RESULT IN COOLANT LEAKS.
9. Secure block heater in 3 o'clock position by hand and torque screw to 2.8-3.6 N.m (25-32 lb-in).
NOTE
IF THE BLOCK HEATER SPINS IN THE CYLINDER BORE MORE THAN 1116 TURN WHILE TORQUING THE SCREW, REMOVE AND DISCARD THE HEATER. ATTEMPTING TO SPIN THE HEATER BACK INTO LOCATION WILL STRETCH THE 0-RING AND RESULT IN COOLANT LEAKS.
10. Reconnect the power cable to the block heater.
11. Reconnect the negative battery cable.
NOTE
REFILL ENGINE COOLING SYSTEM WITH A 50/50 MIXTURE OF PREMIUM COOLING SYSTEM FLUID AND WATER AS OUTLINED IN THE APPLICABLE WORKSHOP OR SERVICE MANUAL, SECTION 303-03-1 (1998 MODEL YEAR) OR SECTION 03-03-1 (1995-97 MODEL YEARS). WHEN BLEEDING THE SYSTEM, RUN THE ENGINE FIRST AT AN IDLE, THEN AT APPROXIMATELY 3000 RPMS TO PREVENT BUBBLES FROM REMAINING IN THE CYLINDER HEAD.
12. Check for leaks around the block heater.