Engine Block Heater - Coolant Leak
Article No.97-17-22
08/18/97
COOLING SYSTEM - COOLANT LEAKING FROM
ENGINE BLOCK HEATER - VEHICLES WITH 4.0L
ENGINE
LIGHT TRUCK:
1995-97 AEROSTAR, EXPLORER, RANGER
ISSUE:
The engine block heater may leak coolant on some vehicles. This may be caused by poor seating of the engine block heater in the engine block.
ACTION:
Install a new engine block heater containing a more robust attaching feature which should reduce the possibility of coolant leaking. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Remove heater element from engine block.
2. Inspect and clean the inside diameter of the core hole, removing any paint or sealer from the machined surface.
3. Examine outer diameter of the core hole and remove any burrs or rough spots to avoid possible damage to block heater 0-ring.
NOTE:
DO NOT USE PETROLEUM BASED LUBRICANT. DO NOT USE SEALER OF ANY TYPE ON MATING SURFACES BETWEEN HEATER AND CORE HOLE.
4. Coat the 0-ring and core hole with anti-freeze.
NOTE:
DO NOT ALLOW THE HEATER TO SPIN DURING ASSEMBLY.
5. Insert the new heater element into the core hole. Push the heater firmly against the engine block wall with the connector in the 12 o'clock position. Torque the capscrew clockwise to 3.7 +/- 0.6 N.m (32.7 +/- 5 lb-in). Refer to Figure 1:
Figure 1, Item # Description
1 Heater Assembly
2 0-Ring And Core Hole
3 "V-Loc" Channel Retainer
4 Clamp Bar
5 Screw (size head)
6 Engine Block
6. Aerostar Explorer/Ranger
Remove the engine block heater Remove the engine block heater
harness locators (four places). wiring harness. Refer to Figures
Replace any locator that is 3 and 4.
damaged during the removal
process. Refer to Figure 2.
7. Aerostar Explorer/Ranger
Loop the harness and reinstall the Reinstall a new engine block
second locator in the boss on the heater harness following the
engine block that the first locator same routing as the previous
was located in. Refer to Figure 2. harness. Proceed to Step 10.
Refer to Figures 3 and 4.
8. Aerostar only: Tie strap the harness to the transmission fill tube near the HEGO connector. Refer to Figure 2.
9. Aerostar only: Tie strap the harness to the transmission fill tube near the Coil pack. Stow the balance of the harness near the engine oil till tube for Customer use. Refer to Figure 2.
10. Refill the engine with Coolant. Adjust the level in the overflow bottle.
11. After the Cooling system has been Completely filled and the Coolant is Cool, remove the radiator Cap and crank the engine without starting by jumping the starter solenoid. Stay back from the radiator until it is apparent that the cranking motor will not spray coolant out of the radiator. Watch the coolant level down the radiator fill neck if it bounces several inches there is additional engine damage due to overheating that must be corrected before the repair is complete. Some movement of the coolant level is normal due to water flow from the pump during this check.
PART NUMBER PART NAME
F77Z-6A051-BA Engine Block Heater
F77Z-6B018-AA Wire Harness
F77Z-6B018-CA Wire Harness
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
971722A Replace Engine Block Heater 0.8 Hr.
DEALER CODING
CONDITION
BASIC PART NO. CODE
6A051 33
OASIS CODES: 205000, 402000, 499000