Attachment III - Technical Information

AFFECTED VEHICLES:
CERTAIN 1996-1997 MODEL YEAR TAURUS AND SABLE VEHICLES EQUIPPED WITH 3.0L VULCAN ENGINES

INSPECTION

1. Open hood.





2. Check for presence of coolant by-pass hose shown in Figure 1.

^ If coolant by-pass hose is present, no service action is required. Return vehicle to customer.

^ If coolant by-pass is not present, proceed to service procedure.

3. Check vehicle mileage.

^ If vehicle mileage is 10,000 miles or more and heavy discoloration (rust) is noted in the coolant, the cooling system must be flushed during the service procedure.

^ If the vehicle mileage is under 10,000 miles, only a cooling system drain and fill is necessary.

SERVICE PROCEDURE

1. Raise vehicle.

2. Remove splash shield.

3. If vehicle mileage is 10,000 miles or more and heavy discoloration (rust) is in the coolant, completely drain and discard cooling system fluid.Then flush cooling system with water as outlined in the 1996/97 Taurus/Sable Service Manual, Section 03-03.

4. If the vehicle mileage is under 10,000 miles, completely drain and discard cooling system fluid.

5. Close radiator draincock.

6. Lower vehicle.

7. Remove clean air tube.





8. Remove coolant recovery hose from fitting shown in Figure 2.








9. With suitable driver, shown in Figure 3, install restrictor insert (F7PE-8N030-AA) as shown in Figure 4. Restrictor insert must be installed flush to the shoulder on the coolant recovery fitting. It is acceptable if the restrictor insert is loose in the fitting.

10. Reinstall coolant recovery hose and clamp.

11. Remove heater return hose from the water pump and heater core return tube.





12. Remove fuel vapor hose clip from the stud on the dash panel. Install the new clip and fasten the nut, securing the clip. Reinstall the fuel vapor hose clip. See Figure 5.





13. Install the coolant by-pass hose at the water pump and at the heater core return tube connection, located at the dash panel. See Figure 6. Install the clamps at both connections inside "H" marking.





14. Remove the heater supply hose from the lower intake manifold, See Figure 7, and leave it hanging loose.

NOTE:
The "H" marking on the hose must be in the straight-up position.

15. Install the coolant by-pass hose to the lower intake manifold heater supply fitting and install clamp inside "H" marking. Refer to Figure 6 and 7.

NOTE:
Check by-pass hose assembly for possible kinks or possible interference with the transmission dipstick and ETA check valve.

16. Cut the heater supply hose approximately 8-1/2 inches from the original connection at the lower intake manifold. Install existing clamp on the remaining heater supply hose. Install the heater supply hose to the "tee" on the coolant by-pass. See Figure 7. Install hose clamp on "tee" connection.

17. Reinstall clean air tube.





18. Push (fasten) new coolant by-pass hose into the new clip on the dash panel. See Figure 8.

19. Raise vehicle.

20. Install splash shield.

21. Lower vehicle.

CAUTION
Use extreme care to keep coolant mixture off of the drive belt and pulleys. If needed, remove drive belt and rinse with clear water. Clean pulleys and install drive belt. Belt squeal and early drive belt fatigue will occur otherwise.

22. Add new 50/50 coolant mixture into till neck on coolant recovery bottle until coolant reaches top of cold fill range mark on bottle.

23. Install pressure relief cap on coolant recovery bottle.

24. Select maximum heater temperature and blower motor speed settings. Position control to discharge air at A/C vents in the instrument panel.

25. Start engine and allow to idle. While engine is idling, feel for hot air at A/C vents.

CAUTION
If air discharge remains cool and engine coolant temperature gauge does not move, engine coolant level is low in engine and must be filled. Stop engine, allow to cool and fill cooling system as described.

26. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from A/C vents. The 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.

27. Shut engine off and allow to cool.

28. Check engine for coolant leaks.