Steps 1-50
Cooling System Flushing - With Fluid Contamination
NOTE: For the coolant flow diagrams, refer to Engine Cooling Engine Cooling 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. Open the radiator draincock and drain the coolant.
7. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.
Pull the lower radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the lower radiator hose quick-connect coupling at the mid-point between the radiator tank and the engine, and drain all the contaminants from the lower radiator hose.
- Connect the lower radiator hose quick-connect coupling when finished.
- To install, push the spring clip in place and connect the lower radiator hose quick connect coupling, making sure the coupling is secure.
8. Release the clamp and disconnect the engine-to-oil cooler hose from the oil cooler and drain the LH cylinder block.
9. Remove the thermostats. For additional information, refer to Thermostat [1][2]Service and Repair.
10. Remove the gasket from the thermostat assembly and install the gasket and the coolant outlet connection.
- Tighten the bolts to 10 Nm (89 lb-in).
11. Remove the Air Cleaner (ACL) and the ACL outlet tube. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.
12. Release the clamp and disconnect the heater return hose from the lower radiator hose.
13. Using a coupling adapter and 2 hose clamps, connect the fabricated fresh water supply hose to the heater return hose.
14. Route the fabricated drain hose from under the vehicle and, using a hose clamp, connect the fabricated drain hose to the lower radiator hose.
15. Using hose pinch pliers, clamp the upper radiator hose, the oil cooler return hose and the lower radiator hose between the mid-point quick connect coupling and the engine.
16. Install the pressure relief cap.
NOTE: Use of hot water during this procedure will improve removal of petroleum based cooling system contaminants.
17. Turn on the fresh water supply and allow the water to flush the cylinder block of contaminants.
18. Turn the water off when finished.
19. Remove the hose pinch pliers from the upper radiator hose.
20. Turn on the fresh water supply and allow the water to flush the radiator of contaminants.
21. Turn the water off when finished.
22. Remove the hose pinch pliers from the lower radiator hose and the oil cooler return hose.
23. Connect the engine-to-oil cooler hose to the oil cooler and position the clamp.
24. Remove the pressure relief cap.
25. Disconnect the fresh water supply hose from the heater return hose and the drain hose from the lower radiator hose.
26. Connect the heater return hose to the lower radiator hose and position the clamp.
27. Close the radiator draincock.
28. Install the ACL and the ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering [1][2]Diagrams.
29. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.
Pull the upper radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling, disconnect the upper radiator hose quick-connect coupling from the coolant outlet connection and add 3.79L (1 gal) of Simple Green(R) to the engine via the coolant outlet connection opening.
- Connect the upper radiator hose when finished.
- To install, push the spring clip in place and connect the upper radiator hose quick connect coupling, making sure the coupling is secure.
30. 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.
31. Select the maximum heater temperature and blower motor speed settings.
32. Start the engine.
33. Using a scan tool, select active command and set the cooling fan to ON.
34. 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.
35. Return the engine to idle speed, shut the engine off and allow the engine to cool.
36. 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.
37. Using a suitable suction devise, siphon all contents and contaminants from the degas bottle.
38. Open the radiator draincock and drain the cooling system.
39. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.
Pull the lower radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling and disconnect the lower radiator hose quick-connect coupling at the mid-point between the radiator tank and the engine, and drain all the contaminants from the lower radiator hose.
40. Release the clamp and disconnect the engine-to-oil cooler hose from the oil cooler and drain the LH cylinder block.
41. Connect the engine-to-oil cooler hose to the oil cooler and position the clamp.
42. Push the spring clip is place and connect the lower radiator hose quick connect coupling, making sure the quick connect coupling is secure.
43. Close the radiator draincock.
44. Repeat steps 29 through 43 an additional 3 times.
NOTICE: After filling the engine with Motorcraft(R) Engine Cooling System Iron Cleaner, carry out the remaining steps of the procedure within 24 hours. Failure to follow these instructions may damage the engine or cooling system.
45. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The quick connect coupling on the hose may differ.
Pull the upper radiator hose spring clip up until the end of the clip is in the detent on the quick connect coupling, disconnect the upper radiator hose quick-connect coupling from the coolant outlet connection and add 1.89L (2 qt) of Motorcraft(R) Engine Cooling System Iron Cleaner to the engine via the coolant outlet connection opening.
- Connect the upper radiator hose when finished.
- To install, push the spring clip in place and connect the upper radiator hose quick connect coupling, making sure the coupling is secure.
46. 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.
47. Select the maximum heater temperature and blower motor speed settings.
48. Start the engine.
49. Using a scan tool, select active command and set the cooling fan to ON.
50. 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.