Thermostat: Service and Repair

WARNING: NEVER REMOVE THE PRESSURE RELIEF CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE COOLING SYSTEM OR RADIATOR COOLANT RECOVERY RESERVOIR (8A080), USE EXTREME CARE WHEN REMOVING THE PRESSURE RELIEF CAP FROM A HOT COOLING SYSTEM OR RADIATOR COOLANT RECOVERY RESERVOIR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE PRESSURE RELIEF CAP AND TURN IT SLOWLY UNTIL PRESSURE BEGINS TO RELEASE. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN CERTAIN ALL PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE PRESSURE CAP (STILL WITH A CLOTH) TURN AND REMOVE PRESSURE RELIEF CAP.

REMOVAL

1. Drain the engine cooling system so that the engine coolant level is below the water thermostat.
2. Remove battery (10653).
3. Disconnect the radiator hoses from the water thermostat housing and remove water thermostat housing.
4. Remove the two water thermostat housing retaining bolts. Separate the water thermostat housings.
5. Remove the O-ring seal and water thermostat from the water thermostat housing. Inspect O-ring for damage and replace.

INSTALLATION
1. Install the water thermostat and new O-ring.
2. Install housing valves and tighten alternately the two retaining bolts. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
3. Install water thermostat housing and connect the radiator hoses to the water thermostat housing.
4. Install battery.
5. Fill the cooling system with Ford Premium Cooling System Fluid E2FZ-19549-AA or-B (in Canada, Motorcraft CXG-8-B) or equivalent meeting Ford specifications ESE-M97B44-A in a 50/50 mixture with water following Filling and Bleeding procedure.