Thermostat: Service and Repair

REMOVAL
1. Drain the engine cooling system so that the engine coolant level is below the water thermostat.

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 DEGAS BOTTLE, USE EXTREME CARE WHEN REMOVING THE PRESSURE RELIEF CAP FROM A HOT COOLING SYSTEM OR DEGAS BOTTLE. 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.

2. Raise vehicle on hoist.
3. Disconnect the lower radiator hose from the water inlet connection.
4. Remove the two water inlet connection retaining bolts. Remove the water inlet connection.
5. Remove the O-ring seal and water thermostat from the water thermostat housing. Inspect O-ring for damage and replace if necessary.
6. If required, remove water thermostat housing retaining bolts, water thermostat housing and O-ring from lower radiator hose tube. Inspect O-ring for damage and replace if necessary.

INSTALLATION
1. Install the water thermostat, O-ring, water thermostat housing (if removed) as shown.
2. Install and alternately tighten the retaining bolts. Tighten bolts to 8-12 Nm (71-106 inch. lbs.).
3. Connect the lower radiator hose to the water inlet connection.
4. Lower vehicle.
5. Fill the cooling system with Premium Cooling System Fluid E2FZ-19549-AA or -B in Oregon, F5FZ-19549-CC, in Canada, CXC-8-B, Recycled Coolant, or equivalent that meets Ford specification ESE-M97B44-A in a 50/50 mixture.
6. Start the engine and check all hoses and connections for leaks. Allow the engine to warm up so that the water thermostat opens.





7. Stop the engine. Top off degas bottle as required to maintain minimum cold fill level.