Powertrain Secondary Cooling System Flushing - with Fluid Contamination
Cooling System Flushing - With Fluid Contamination
NOTE: For the coolant flow diagram, refer to Powertrain Secondary Cooling System Powertrain Secondary Cooling System in the Description and Operation information.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.
2. Fabricate a fresh water supply hose.
- Cut the garden hose to length. The hose must reach from a fresh water supply faucet to the vehicle.
- NOTE: The heater hose will prevent kinking in tight areas of the engine compartment.
Using a coupling adapter and 2 hose clamps, attach a 61 cm (2 ft) length of heater hose to the garden hose.
3. Fabricate a drain hose.
- NOTE: The heater hose will prevent kinking in tight areas of the engine compartment.
Using a coupling adapter and 2 hose clamps, attach a 61 cm (2 ft) length of heater hose to the remaining section of the garden hose to be used as a drain hose.
4. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.
Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn counterclockwise. When the pressure is released, remove the pressure relief cap.
5. Using a suitable suction devise, siphon all contents and contaminants from the degas bottle.
6. Remove the low temperature thermostat. For additional information, refer to Thermostat - Low Temperature Powertrain Secondary Cooling System - Thermostat - Low Temperature.
7. Install the low temperature thermostat cover and the bolts.
- Tighten to 5 Nm (44 lb-in).
8. Release the clamp and disconnect the EGR cooler-to-degas bottle hose from the EGR cooler.
9. Using a coupling adapter and 2 hose clamps, connect the fabricated fresh water supply hose to the EGR cooler-to-degas bottle hose.
10. Using a hose clamp, connect the fabricated drain hose to the EGR cooler-to degas bottle hose fitting on the EGR cooler.
11. Release the clamp and disconnect the radiator-to-transmission fluid cooler hose from the transmission cooler.
NOTE: Use of hot water during this procedure will improve removal of cooling system contaminants.
12. Turn on the fresh water supply and allow the water to flush the ERG cooler and the transmission fluid cooler.
13. Turn off the fresh water supply.
14. Connect the radiator-to-transmission fluid cooler hose to the transmission fluid cooler and position the clamp.
15. Disconnect the fuel cooler-to-degas bottle hose from the fuel cooler.
16. Turn on the fresh water supply and allow the water to flush the Charge Air Cooler (CAC).
17. Turn off the fresh water supply.
18. Using hose pinch pliers, clamp the disconnected fuel cooler-to-degas bottle hose.
19. Turn on the fresh water supply and allow the water to flush the fuel cooler.
20. Turn off the fresh water supply.
21. Remove the hose pinch pliers, connect the fuel cooler-to-degas bottle hose to the fuel cooler and position the clamp.
22. Disconnect the fabricated fresh water supply hose from the EGR cooler-to-degas bottle hose and the fabricated drain hose from the EGR cooler-to-degas bottle hose fitting.
23. Connect the EGR cooler-to-degas bottle hose to the EGR cooler and position the clamp.
24. Close the radiator draincock.
25. Remove the degas bottle. For additional information, refer to Degas Bottle Powertrain Secondary Cooling System - Degas Bottle.
26. Clean the degas bottle in a solvent tank.
27. Install the degas bottle. For additional information, refer to Degas Bottle Powertrain Secondary Cooling System - Degas Bottle.
28. Fill the secondary cooling system with 3.79 L (1 gal) of Simple Green(R) and water.
1. Fill the degas bottle to the maximum fill line.
2. NOTE: The degas bottle cap must be loose so that the cooling system does not get pressurized.
Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
3. Start and idle the engine until the coolant level stabilizes.
4. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
5. Run the engine at 2,000 rpm for 2 minutes.
6. Bring the engine to an idle.
7. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
8. Repeat Steps 5 through 7 until the coolant level stabilizes. Shut the engine off.
9. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line. Install the degas bottle cap.
29. Start the engine.
30. NOTICE: Failure to run the engine at 2,000 rpm for 1 hour will result in insufficient cleaning of the cooling system.
Using a scan tool, select active command and set the engine rpm to 2,000 and run the engine for 1 hour.
31. Return the engine to idle speed, shut the engine off and allow the engine to cool.
32. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.
Release the pressure in the cooling system by slowly turning the pressure relief cap 1/2 turn counterclockwise. When the pressure is released, remove the pressure relief cap.
33. Using a suitable suction device, siphon all contents and contaminants from the degas bottle.
34. Open the secondary radiator draincock and drain the cooling system.
35. Release the clamp, disconnect the radiator-to-transmission fluid cooler hose and drain the high temperature side of the secondary cooling system.
36. Release the clamp, disconnect the fuel cooler-to-degas bottle hose and drain the low temperature side of the secondary cooling system.
37. Close the radiator draincock.
38. Connect the radiator-to-transmission fluid cooler hose and position the clamp.
39. Connect the fuel cooler-to-degas bottle hose and position the clamp.
40. Repeat steps 28 through 39 once.
41. Fill the secondary cooling system with 1.89L (0.5 gal) of Simple Green(R) and water
1. Fill the degas bottle to the maximum fill line.
2. NOTE: The degas bottle cap must be loose so that the cooling system does not get pressurized.
Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
3. Start and idle the engine until the coolant level stabilizes.
4. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
5. Run the engine at 2,000 rpm for 2 minutes.
6. Bring the engine to an idle.
7. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
8. Repeat Steps 5 through 7 until the coolant level stabilizes. Shut the engine off.
9. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line. Install the degas bottle cap.
42. Repeat steps 29 through 39 once.
43. NOTICE: After filling the secondary cooling system with Motorcraft(R) Premium Cooling System Flush, carry out the remaining steps of this procedure within 24 hours. Failure to follow these instructions may damage the cooling system.
Fill the secondary cooling system with 0.95L (1 qt) of Motorcraft(R) Premium Cooling System Flush and water.
1. Fill the degas bottle to the maximum fill line.
2. NOTE: The degas bottle cap must be loose so that the cooling system does not get pressurized.
Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
3. Start and idle the engine until the coolant level stabilizes.
4. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
5. Run the engine at 2,000 rpm for 2 minutes.
6. Bring the engine to an idle.
7. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
8. Repeat Steps 5 through 7 until the coolant level stabilizes. Shut the engine off.
9. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line. Install the degas bottle cap.
44. NOTICE: Failure to run the engine at 2,000 rpm for 1 hour will result in insufficient cleaning of the cooling system.
Using a scan tool, select active command and set the engine rpm to 2,000 and run the engine for 1 hour.
45. Return the engine to idle speed, shut the engine off and allow the engine to cool.
46. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.
Release the pressure in the cooling system by slowly turning the pressure relief cap 1/2 turn counterclockwise. When the pressure is released, remove the pressure relief cap.
47. Open the secondary radiator draincock and drain the cooling system. Leave the draincock open.
48. Release the clamp, disconnect the radiator-to-transmission fluid cooler hose from the transmission fluid cooler and drain the high temperature side of the secondary cooling system.
49. Release the clamp, disconnect the fuel cooler-to-degas bottle hose from the fuel cooler and drain the low temperature side of the secondary cooling system.
50. Close the radiator draincock.
51. Connect the radiator-to-transmission fluid cooler hose and position the clamp.
52. Connect the fuel cooler-to-degas bottle hose and position the clamp.
53. Release the clamp and disconnect the EGR cooler-to-degas bottle hose from the EGR cooler.
54. Using a coupling adapter and 2 hose clamps, connect the fabricated fresh water supply hose to the EGR cooler-to-degas bottle hose.
55. Using a hose clamp, connect the fabricated drain hose to the EGR cooler-to degas bottle hose fitting on the EGR cooler.
56. NOTICE: Failure to flush all the Motorcraft(R) Premium Cooling System Flush from the cooling system will result in shortened coolant protection against corrosion of the cooling system.
Turn on the fresh water supply to flush the secondary cooling system until the water is free of foam, bubbles or discoloration. Use a clear, clean approximately 1 L (1 qt) container to verify the drain water is clear.
57. Turn off the fresh water supply.
58. Open the secondary radiator draincock and drain the cooling system. Use a clear, clean approximately 1 L (1 qt) container to verify the drain water is clear of foam, bubbles or discoloration. Close the radiator draincock when finished.
59. Release the clamp and disconnect the radiator-to-transmission fluid cooler hose from the transmission fluid cooler and drain the high temperature side of the secondary cooling system. Use a clear, clean approximately 1 L (1 qt) container to verify the drain water is clear of foam, bubbles or discoloration. Connect the radiator-to-transmission fluid cooler hose to the transmission fluid cooler and position the clamp when finished.
60. Release the clamp, disconnect the fuel cooler-to-degas bottle hose and drain the low temperature side of the secondary cooling system. Use a clear, clean approximately 1 L (1 qt) container to verify the drain water is clear of foam, bubbles or discoloration. Connect the fuel cooler-to-degas bottle hose and position the clamp when finished.
61. If any of the drain water in steps 58 through 60 shows signs of foam, bubbles or discoloration, repeat steps 56 through 60.
62. Disconnect the fresh water supply and drain hoses from the EGR cooler-to-degas bottle hose and the EGR cooler-to-degas bottle hose fitting on the EGR cooler.
63. Connect the EGR cooler-to-degas bottle hose to the EGR cooler and position the clamp.
64. Remove the degas bottle. For additional information, refer to Degas Bottle Powertrain Secondary Cooling System - Degas Bottle.
65. Clean the degas bottle in a solvent tank.
66. Install the degas bottle. For additional information, refer to Degas Bottle Powertrain Secondary Cooling System - Degas Bottle.
67. Fill the secondary cooling system with low hardness, low chloride water. Tap water which is verified with Rotunda Water Test Strip 5 pack 328-00007 or equivalent is acceptable. Alternatively, use water treated by reverse osmosis, or water that is de-ionized or distilled.
Fill the cooling system with hot water.
1. Fill the degas bottle to the maximum fill line.
2. NOTE: The degas bottle cap must be loose so that the cooling system does not get pressurized.
Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
3. Start and idle the engine until the coolant level stabilizes.
4. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
5. Run the engine at 2,000 rpm for 2 minutes.
6. Bring the engine to an idle.
7. If the coolant level drops below the minimum fill line refill the degas bottle to the maximum fill line.
- Install the degas bottle cap until it starts to ratchet. Back the degas bottle cap off one-half turn.
8. Repeat Steps 5 through 7 until the coolant level stabilizes. Shut the engine off.
9. Fill the degas bottle to 20 mm (0.787 in) above the maximum fill line. Install the degas bottle cap.
68. Open the secondary radiator draincock and drain the cooling system.
69. Remove and discard the radiator draincock.
70. Release the clamp and disconnect the radiator-to-transmission fluid cooler hose from the transmission fluid cooler and drain the high temperature side of the secondary cooling system.
71. Release the clamp, disconnect the fuel cooler-to-degas bottle hose from the fuel cooler and drain the low temperature side of the secondary cooling system.
72. Install a new secondary radiator draincock, making sure the draincock is closed.
73. Connect the radiator-to-transmission fluid cooler hose to the transmission fluid cooler and position the clamp.
74. Connect the fuel cooler-to-degas bottle hose to the fuel cooler and position the clamp.
75. Install the low temperature thermostat and a new O-ring seal. For additional information, refer to Thermostat - Low Temperature Powertrain Secondary Cooling System - Thermostat - Low Temperature.
76. Install a new high temperature thermostat O-ring seal. For additional information, refer to Thermostat - High Temperature Powertrain Secondary Cooling System - Thermostat - High Temperature.
77. Fill and bleed the cooling system with the correct mixture of engine coolant and distilled water. For additional information, refer to Cooling System Draining, Filling and Bleeding Powertrain Secondary Cooling System Draining, Filling and Bleeding.
78. Install a new pressure relief cap.