radiator FORD MUSTANG 2003 Manual PDF

REMOVAL AND INSTALLATION
Bypass Tube —
Cobra
Removal and Installation 1. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Disconnect the radiator upper hose and the radiator lower hose.
3. Remove the supercharger belt. For additional information, refer to Section 303 - 05 .
4. Disconnect the engine coolant temperature sensor electrical connector and unclip the wiring harness from the stud.
5. NOTE: LH is shown, RH is similar.
Remove the coolant bypass nuts.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B)
(yellow color) WSS-
M97B51-
A1 Klj . 1 ba
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REMOVAL AND INSTALLATION
Bypass Tube —
Mach I
Removal and Installation 1. Remove the air intake scoop and bracket. For additional information, refer to Section 303 - 12 .
2. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
3. Disconnect the upper radiator hose from the bypass tube.
4. Disconnect the lower radiator hose. 5. Disconnect the engine temperature control (ECT) sensor electrical connector. SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B)
(yellow color) WSS-
M97B51-
A1 Klj . 1 ba
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REMOVAL AND INSTALLATION
Water Pump —
3.8L
Removal and Installation 1. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Loosen the coolant pump pulley bolts.
3. Remove the power steering (PS) pump pulley. For additional information, refer to Section 211 -
02 .
4. Remove the bolts and the coolant pump pulley.
5. Remove the PS bracket. zRemove the bolts.
z Remove the nuts. 6. Disconnect the lower radiator hose from the coolant pump. SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B)
(yellow color) WSS-
M97B51-
A1 Klj . 1 ba
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REMOVAL AND INSTALLATION
Radiator
Removal and Installation
NOTE:
Radiator removal and installation is similar for both 3.8L and 4.6L vehicles. The art shown in
the procedure is the 4.6L engine.
Mach I
1. Remove the air intake scoop. For additional information, refer to Section 303 - 12 .
All vehicles 2. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
3. Remove the radiator sight shield. zRelease the clips.
4. Remove the fan blade, fan motor and fan shroud assembly. For additional information, refer to Cooling Fan Motor and Shroud in this section.
5. Remove the upper radiator hose from the radiator.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Material
Item Specification
Motorcraft Premium Gold
Engine Coolant
VC
-7-A (in Oregon VC-7- B)
(yellow color) WSS-
M97B51-
A1 Klj . 1 ba
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6.
NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench.
If equipped, remove the transmission lower cooler tube fitting.
7. NOTE: To avoid disturbing the transmission oil cooler fittings, use a backup wrench.
If equipped, remove the upper transmission cooler tube fitting.
8. Remove the lower radiator hose from the radiator. Klj . 2 ba
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9. Remove the radiator supports.
10. Remove the radiator.
11. To install, reverse the removal procedure.
12. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
Mach I 13. Install the air intake scoop. For additional information, refer to Section 303 - 12 . Klj . 3 ba
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REMOVAL AND INSTALLATION
Degas Bottle —
4.6L(2V) and 4.6L(4V)
Removal and Installation 1. Drain the engine coolant from the degas bottle only. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Disconnect the radiator vent hose.
3. Remove the degas bottle return hose.
4. Remove the nuts and the degas bottle.
5. To install, reverse the removal procedure.
6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
SECTION 303-
03A: Engine Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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SPECIFICATIONS
a
Use the same type coolant that was drained from the cooling system. Do not mix coolant types.
b The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft Premium
Gold Engine Coolant from yellow to golden tan. SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual General Specifications
Item Specification
Cooling System Capacity
System capacity L (qts) 3.75 (4.0)
Coolant Type
Motorcraft Premium Engine Coolant VC-4-
A (CXC-10 in
Canada, VC- 5 in Oregon) a ESE-
M97B44- A Motorcraft Premium Gold Engine Coolant VC-7-
A (in
Oregon VC-7- B)
a b WSS-
M97B51- A1 Other Chemicals
Premium Cooling System Flush VC-
1 ESR-
M14P7-A Premium Long Life Grease XG-1-
C ESA-
M1C75- B Cooling System Stop Leak Pellets
VC-
6 ESE-
M99B37- 5 except as noted in ES-
F65E-19A511- AA Cooling System Pressure Test Specifications
System (radiator) kPa (psi) 138 (20)
System (intercooler) kPa (psi) 138 (20)
Cap (relief opening pressure)
kPa (psi) 69 (10)
Torque Specifications Description Nm lb-
ft lb-
in Water pump bolts 20 — 15
Dropping resistor screw 6 53 —
Degas bottle bolt 10 89 —
Intercooler radiator support bracket-
to-bumper bolts 12 — 9
Intercooler radiator support bracket bolts 10 89 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Supercharger Cooling
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
NOTE: The air that is produced from the supercharger is cooled by the intercooler.
Walter C. Avrea, the owner of patents 3,601,181 and RE 27,965, has granted Ford Motor Company
rights with respect to cooling systems covered by these patents.
The cooling system components include the:
zintercooler
z intercooler radiator (8K226)
z pressure relief cap
z degas bottle
z electric water pump (8501)
The degas bottle:
zprovides a location for system fill.
z contains coolant expansion and system pressurization.
z provides air separation during operation.
z replenishes the intercooler coolant to the system.
The intercooler coolant flows:
zfrom the intercooler to the degas bottle.
z from the degas bottle to the water pump.
z from the water pump to the intercooler radiator.
z from the intercooler radiator to the intercooler.
Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to
the engine and cooling components. In order to obtain these protections, the engine coolant must be
maintained at the correct concentration and fluid level in the degas bottle.
When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water.
To maintain the integrity of the coolant and the cooling system: SECTION 303-
03B: Supercharger Cooling 2003 Mustang Workshop Manual Klj . 1 ba
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CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine
Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting Ford specification
ESE- M97B44- A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant
VC -7-A or equivalent meeting Ford specification WSS- M97B51-A1 (yellow color). Always fill the
cooling system with the same coolant that is present in the system. Do not mix coolant types.
NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC- 6, darkens Motorcraft
Premium Gold Engine Coolant from yellow to golden tan.
1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply.
3. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary.
4. Inspect the coolant condition. 1. WARNING: Never remove the pressure relief cap while the engine is
operating or when the cooling system is hot. Failure to follow these instructions
can result in damage to the cooling system or engine or personal injury. To avoid
having scalding hot coolant or steam blow out of the degas bottle when removing
the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth
around the pressure relief cap and turn it slowly. Step back while the pressure is
released from the cooling system. When you are sure all the pressure has been
released, (still with a cloth) turn and remove the pressure relief cap.
Allow the engine to cool. Once pressure is released, remove the pressure relief cap.
2. CAUTION: Check the coolant and engine oil level and top off the coolant if
needed. If there is engine coolant in the engine oil the cause must be corrected
and oil/fluid changed or major component damage can occur.
CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium
Engine Coolant VC -4-A (in Oregon VC- 5, in Canada CXC- 10) or equivalent meeting
Ford specification ESE- M97B44-A (green color). Others are filled with Motorcraft
Premium Gold Engine Coolant VC -7-A or equivalent meeting Ford specification
WSS- M97B51- A1 (yellow color). Always fill the cooling system with the same
coolant that is present in the system. Do not mix coolant types.
Inspect the coolant color:
„If Motorcraft Premium Engine Coolant (green color) VC-4- A or equivalent meeting
Ford specification ESE-M97B44- A has a clear, light green or blue color, this Visual Inspection Chart
Mechanical Electrical
z
Radiator brackets
z Leaks
z Damaged hoses
z Hose clamps
z Water pump
z Radiator
z Degas bottle
z Water pump bracket z
Damaged water pump wiring Klj . 2 ba
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