Attachment III - Technical Information
BLOCK HEATER REPLACEMENTAFFECTED VEHICLES:
1995-1998 CONTOUR/MYSTIQUE AND 1998 ESCORT ZX2 EQUIPPED WITH 2.0L ZETEC ENGINE AND (OPTIONAL) ENGINE BLOCK HEATER
SERVICE PROCEDURE
1. Install memory saver, then disconnect battery negative cable.
2. When engine is cold, remove coolant recovery bottle pressure cap. (Radiator cap ZX2 only).
3. Raise and support vehicle.
4. Remove splash shield (Contour/Mystique only).
5. Completely drain cooling system fluid and discard.
6. Disconnect power cable from block heat.
7. Loosen block heater retaining screw. See Figure 1. Back screw out slowly until until a slight resistance is felt.
CAUTION
Use a caution to prevent scratching the cylinder block bore.
8. Unseat block heater from cylinder block, then remove block heater by tipping the heater and guiding the inner crossbar out of the cylinder block hole. Pry the crossbar with a screwdriver to aid removal. See Figure 2.Discard old block heater.
9. Using a emery cloth, clean cylinder block bore surface.
10. Check machined surface of the block heater hole for nicks, scratches and excessive corrosion.
11. Coat new block heater O-ring with a liberal amount of dielectric silicone (WA-10).
12. Install block heater (-6A051-), fully seated, into cylinder block bore with power cable connector at the 3 o'clock position. See Figure 3.
CAUTION
Do not over-torque block heater screw. A coolant leak will result.
NOTE:
If block heater spins more than 1/16 of a turn (4 o'clock position as shown in Figure 4) in the cylinder block bore while torquing the screw, remove, destroy and discard block heater. DO NOT attempt to spin the block heater back into position. Doing so will result in a coolant leak.
13. Secure the block heater in the 3 o'clock position with one hand and torque block heater retaining screw to 3.2 Nm (28 lb-in).
14. Connect power cable to block heater.
15. Install splash shield (Contour/Mystique only).
16. Lower vehicle.
17. Connect battery negative cable, then remove memory saver.
18. On Contour and Mystique, fill cooling system as follows:
^ Fill cooling system with a 50/50 mixture of new Premium Cooling System fluid (-19549-) and water to the MAX line on the coolant recovery bottle.
^ To bleed the cooling system, alternate engine rpm between idle and 3000 rpm, until engine reaches normal operating temperature (thermostat opens and upper radiator hose is hot).
^ Top off with water to the "MAX" line on the coolant recovery bottle, if necessary.
^ Reinstall coolant recovery bottle pressure cap.
19. On Escort ZX2, fill cooling system as follows:
^ Fill cooling system with a 50/50 mixture of new Premium Cooling System fluid (-19549-) and water to 2 inches below the radiator filler neck.
^ Start engine and idle until engine reaches normal operating temperature (thermostat opens and upper radiator hose is hot). Top off with water to the bottom of the radiator filler neck, if necessary.
^ Reinstall radiator cap.
20. On all models, select maximum heater temperature and blower motor speed settings. Position control discharge air to panel vents in the instrument panel.
CAUTION
If air discharge remains cool and the engine coolant temperature gauge does not move, engine coolant level is low and must be filled. Stop engine, allow to cool and fill cooling system as described.
21. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from panel vents. Engine coolant temperature gauge should maintain a stabilized reading to within the NORMAL range and the upper radiator hose should feel hot to the touch.
22. Shut off engine and allow to cool.
NOTE:
If leak is present at the block heater, DO NOT RE-TORQUE block heater screw. Remove the block heater and replace it. Return to Step 10 and recheck bore condition and proceed with service repair procedure.
23. Check cooling system for leaks.