303-03-i Engine Cooling 303-03-i

SECTION 303-03 Engine Cooling

CONTENTS PAGE

GENERAL PROCEDURES
Cooling System Flushing — Diesel Engine ......................................................................................................................... 303-03-2

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GENERAL PROCEDURES
Cooling System Flushing — Diesel Engine
Special Tool(s)

Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software
with appropriate hardware, or equivalent scan tool

Material
Item Specification
Motorcraft® Engine Cooling System Iron Cleaner —
VC-9
Motorcraft® SAE 15W-40 Super Duty Diesel Motor Oil WSS-M2C171-E
XO-15W40-QSD (US); CXO-15W40-LSD12 (Canada); or equivalent

NOTICE:
This procedure should be used to clean and flush the diesel cooling system to make sure that all rust is removed from the system. Failure to follow
these instructions may result in engine damage.

NOTICE:
If oil or fuel is present in the cooling system, refer to the appropriate Technical Service Bulletins (TSBs) that pertain to 6.0L diesel engine cooling
system concerns and follow the procedure outlined. Failure to remove all contaminants from the cooling system may result in engine damage.

1.
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.

Once pressure is released, remove the pressure relief cap.

• Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Remove the Air Cleaner (ACL) element. For additional information, refer to Section 303-12.
3. Disconnect the air filter minder and the Mass Air Flow (MAF) electrical connectors.

4. Loosen the clamp and remove the rear ACL cover.

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GENERAL PROCEDURES (Continued)

5. Disconnect the upper radiator hose from the thermostat housing assembly.

6. Remove the bolts and the thermostat housing assembly.

7. Position the thermostat housing assembly in the vise. Press down on the thermostat crossbar and rotate the thermostat to remove it from the thermostat
housing assembly.

8. NOTE:
Use the old O-ring seal during the flushing procedure.

Install the thermostat housing assembly without the thermostat. Install the bolts.
• Tighten to 23 Nm (17 lb-ft).

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GENERAL PROCEDURES (Continued)

9. Connect the upper radiator hose to the thermostat housing assembly.

10. Install the rear ACL cover and tighten the clamp.

11. Connect the air filter minder and the MAF electrical connectors.

12. Install the ACL element. For additional information, refer to Section 303-12.
13. NOTE:
The RH cylinder block drain plug is not removed at this time.

Remove the LH cylinder block drain plug and drain the cylinder block.

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GENERAL PROCEDURES (Continued)

14. NOTE:
Lightly lubricate the O-ring seal on the cylinder block drain plug with clean engine oil before installing.

Install the LH cylinder block drain plug.

• Tighten to 20 Nm (177 lb-in).

15. NOTE:
For vehicles with auxiliary climate control or commercial vehicles with auxiliary heaters, use 2.83L (3 qt) of Motorcraft® Engine Cooling System
Iron Cleaner (VC-9).

NOTE:
The use of excessive Motorcraft® Engine Cooling System Iron Cleaner (VC-9) can lead to gelling.

Fill the cooling system with water and 1.89L (2 qt) of Motorcraft® Engine Cooling System Iron Cleaner (VC-9).
16. NOTE:
Adjust the heater control to the full hot position to allow coolant flow during the cooling system flush.

NOTE:
Failure to allow the engine to run for one hour will result in insufficient cleaning of the cooling system.

Using the scan tool, select the active command and set the engine rpm to 1,175. Run the engine for one hour.
17.
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.

Once pressure is released, remove the pressure relief cap.

• Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
• Leave the radiator draincock open.
18. Remove the LH cylinder block drain plug.

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GENERAL PROCEDURES (Continued)

19. Remove the starter. For additional information, refer to Section 303-06B.
20. Remove the RH cylinder block drain plug.

21. NOTE:
For vehicles with a standard heater, disconnect the vacuum hose at the heater control valve to open the heater core flow. For vehicles with
anElectronic Automatic Temperature Control (EATC) heater, turn the ignition key to the ON position.

NOTE:
Failure to flush all the Motorcraft® Engine Cooling System Iron Cleaner (VC-9) from the cooling system will result in shortened coolant protection
against corrosion.

Flush the cooling system with clean water through the degas bottle to completely remove the Motorcraft® Engine Cooling System Iron Cleaner
(VC-9) from the cooling system.
• Flush the cooling system with clean water until no foam or discoloration is draining from the cooling system.
22. Backflush the heater core. For additional information, refer to Heater Core Backflushing in this section.
23. NOTE:
Failure to flush all the Motorcraft® Engine Cooling System Iron Cleaner (VC-9) from the cooling system will result in shortened coolant protection
against corrosion.

Flush the cooling system with clean water through the degas bottle to completely remove the Motorcraft® Engine Cooling System Iron Cleaner
(VC-9) from the cooling system.
• Flush the cooling system with clean water until no foam or discoloration is draining from the cooling system.
24. Close the radiator draincock.
25. Remove the ACL element. For additional information, refer to Section 303-12.
26. Disconnect the air filter minder and the MAF electrical connectors.

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GENERAL PROCEDURES (Continued)

27. Loosen the clamp and remove the rear ACL cover.

28. Disconnect the upper radiator hose from the thermostat housing assembly.

29. Remove the bolts and the thermostat housing assembly.

• Remove and discard the O-ring seal.

30. Position the thermostat housing assembly in the vise. Press down on the thermostat crossbar and rotate the thermostat to install it in the thermostat
housing assembly.

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GENERAL PROCEDURES (Continued)

31. NOTE:
Install a new O-ring seal.

Install the thermostat housing assembly and the bolts.

• Tighten to 23 Nm (17 lb-ft).

32. Connect the upper radiator hose to the thermostat housing assembly.

33. Install the rear ACL cover and tighten the clamp.

34. Connect the air filter minder and the MAF electrical connectors.

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GENERAL PROCEDURES (Continued)

35. Install the ACL element. For additional information, refer to Section 303-12.
36. NOTE:
Lightly lubricate the O-ring seal on the cylinder block drain plug with clean engine oil before installing.

Install the RH cylinder block drain plug.

• Tighten to 20 Nm (177 lb-in).

37. Install the starter. For additional information, refer to Section 303-06B.
38. NOTE:
Lightly lubricate the O-ring seal on the cylinder block drain plug with clean engine oil before installing.

Install the LH cylinder block drain plug.

• Tighten to 20 Nm (177 lb-in).

39. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

Block Heater — Gasoline Engines ...................................................................................................................................... 303-03-2

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303-03-2 Engine Cooling 303-03-2

Block Heater — Gasoline Engines

Item Part Number Description

1 14A199 Block heater electrical connector
2 — Block heater retaining screw (part of 6A051)
3 6A051 Block heater

Removal and Installation

1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. NOTICE:
Do not loosen the block heater retaining screw more than necessary for removal. The nut can fall off inside the engine and damage the
cooling system.

Loosen the block heater retaining screw and remove the block heater.
• To install, tighten to 4 Nm (35 lb-in).
3. NOTICE:
Route the block heater power cable away from hot or rotating components, or damage to the cable can occur.

To install, reverse the removal procedure.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

Thermostat — 5.4L, 6.8L ..................................................................................................................................................... 303-03-2

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303-03-2 Engine Cooling 303-03-2

Thermostat — 5.4L, 6.8L

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31

Item Part Number Description

1 15161 Upper radiator hose clamp
2 8B274 Upper radiator hose
3 W503279 Thermostat housing bolts (2 required)
4 8594 Thermostat housing
5 N806807 Thermostat O-ring seal
6 8575 Thermostat

Removal and Installation

1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12.
3. If servicing the thermostat housing, disconnect the upper radiator hose from the thermostat housing.
4. Remove the 2 bolts, position the thermostat housing aside and remove the thermostat. Discard the O-ring seal.
• Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
• Install a new O-ring seal.
• To install, tighten to 10 Nm (89 lb-in).
5. To install, reverse the removal procedure.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

Coolant Pump — 6.0L Diesel .............................................................................................................................................. 303-03-2

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303-03-2 Engine Cooling 303-03-2

Coolant Pump — 6.0L Diesel

Special Tool(s)

Wrench, Fan Clutch Nut

303-591

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31

Item Part Number Description

1 N806282 Coolant pump pulley bolt (4 required)
2 8A528 Coolant pump pulley
3 N808794 Coolant pump bolt (4 required)
4 8501 Coolant pump
5 391108 Coolant pump O-ring seal

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
3. Remove the cooling fan stator. For additional information, refer to Cooling Fan Stator — 6.0L Diesel in this section.
4. Rotate the accessory drive belt tensioner clockwise and position the drive belt aside.

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303-03-3 Engine Cooling 303-03-3
(Continued)

5. Remove the bolts and the coolant pump pulley.

• To install, tighten to 31 Nm (23 lb-ft).
6. Remove the bolts, the coolant pump and discard the O-ring seal.
• Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
• Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation.
• To install, tighten to 23 Nm (17 lb-ft).
7. To install, reverse the removal procedure.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

GENERAL PROCEDURES
Coolant Test — Diesel Engine ............................................................................................................................................. 303-03-2

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303-03-2 Engine Cooling 303-03-2

GENERAL PROCEDURES
Coolant Test — Diesel Engine
Special Tool(s)

3-Way HD Antifreeze Coolant Test Kit

328-00001 or equivalent

Material
Item Specification
Motorcraft® Diesel Cooling System Additive ESN-M99B169-A
VC-8

1. Inspect the coolant condition. If the coolant is clean and a normal color, proceed with the test. If the coolant is dirty or an unusual color, refer to
Inspection and Verification in Diagnosis and Testing.
2. NOTE:
Failure to follow the service procedure as indicated may result in inaccurate test results.

NOTE:
Check the expiration date on the 3-Way HD Antifreeze Coolant Test Kit before starting the test.

Start with clean, dry hands and tools.

3. NOTE:
The coolant sample may be collected from the degas bottle only if the vehicle has been driven at least 1600 km (1000 miles) since the last time
coolant was added, otherwise collect the coolant sample from the radiator draincock.

NOTE:
The coolant sample must be between 10°C (50°F) and 54°C (130°F) when tested or inaccurate readings may result.

Collect a coolant sample from the degas bottle using the syringe or drain from the radiator draincock.
4. NOTE:
Do not touch the pads on the antifreeze and anticorrosion strength test strip or inaccurate readings may result.

NOTE:
Discard the test strip if the nitrite test pad (end closest to the handle) has turned brown.

NOTE:
Replace the cap on the bottle immediately after removing the test strip.

Remove one test strip from the bottle.

5. NOTE:
For best results, follow test times carefully. Use a stopwatch or clock with a sweeping second hand.

Dip the strip in the coolant sample for one second, remove and shake the strip briskly to remove the excess.
• Wait 45 seconds, but no longer than 75 seconds, after dipping the strip to compare and record the results.
6. NOTE:
It is OK to estimate a value between color blocks, but if uncertain about the color match, pick the block with the lower nitrite level.

Check the strip and record the results.

1 Compare the freeze point (end pad) to the color chart on the bottle and record the results.
2 Compare the nitrite test (end closest to the handle) to the color chart on the bottle and record the results.
3 The middle pad is for molybdate which is not a performance measurement used in determining maintenance requirements for these applications.

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303-03-3 Engine Cooling 303-03-3
GENERAL PROCEDURES (Continued)

7. Check the nitrite levels.

• If the nitrite level exceeds 800 parts per million, anticorrosion strength meets specifications, no action is required.
• If the nitrite level is between 300 parts per million and 800 parts per million, anticorrosion strength is low. Add one bottle of Motorcraft® Diesel
Cooling System Additive.
• If nitrite level is below 300 parts per million, anticorrosion strength is very low and cannot be restored. Proceed to step 9.
8. Verify that the freeze point is appropriate for the climate.
• If the coolant tests weak, remove some of the coolant and add undiluted engine coolant until the readings are within acceptable levels.
• If the coolant tests strong, remove some of the coolant and add distilled water until the readings are within acceptable levels.
9. NOTICE:
Do not add Motorcraft® Diesel Cooling System Additive when refilling the cooling system after a cooling system flush with Motorcraft®
Engine Cooling System Iron Cleaner. This may lead to possible engine damage due to very high levels of nitrite concentrations.

Flush the cooling system. For additional information, refer to Cooling System Flushing — Diesel Engine in this section.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding ................................................................................................................... 303-03-2
Draining ........................................................................................................................................................................ 303-03-2
Filling and Bleeding with RADIATOR REFILLER ......................................................................................................... 303-03-2
Filling and Bleeding without RADIATOR REFILLER .................................................................................................... 303-03-3

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303-03-2 Engine Cooling 303-03-2

GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding
Special Tool(s)

RADIATOR REFILLER
078-00592

Material
Item Specification
Motorcraft® Premium Gold Engine Coolant WSS-M97B51-A1
VC-7-B (US); CVC-7-B (Canada); or equivalent

Draining

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.

NOTICE:
Always fill the cooling system with the same type of coolant that was drained from the system. Do not mix coolant types. Failure to follow these
instructions may result in damage to the cooling system.

NOTICE:
The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly
and the system filled with new coolant. Failure to follow these instructions may result in damage to the cooling system.

NOTE:
Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.

1. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the fluid cooler.
2. Remove the pressure relief cap from the degas bottle.
3. Open the radiator draincock and drain the coolant into a suitable container.
4. Close the radiator draincock when finished.

Filling and Bleeding with RADIATOR REFILLER

1. NOTICE:
With the engine cold, fill vehicles to within the cold fill range shown on the degas bottle. This fill level will allow for coolant expansion.
Overfilling the degas bottle may result in damage to the pressure cap, which can cause the engine to overheat.

NOTICE:
For diesel engine, do not add Motorcraft® Diesel Cooling System Additive when refilling the cooling system with new coolant. An excessive
amount of additive may cause formation of gels that may cause coolant flow restriction, plugging of passages and overheating.

NOTICE:
For diesel engine, when refilling the cooling system with new coolant, verify that the specified coolant is used. Not all coolants contain a
nitrite additive package. Failure to have nitrite in the cooling system may result in major corrosive damage to the engine cooling system
components.

NOTE:
For diesel engine, when reusing the coolant that was drained from the cooling system, check the antifreeze and anticorrosion level of the coolant.
Refer to Coolant Test — Diesel Engine in this section.

Install the RADIATOR REFILLER and follow the manufacturer's instructions to fill and bleed the cooling system.

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303-03-3 Engine Cooling 303-03-3
GENERAL PROCEDURES (Continued)
• Recommended coolant concentration is 50/50 ethylene glycol to distilled water.
▪ Maximum coolant concentration is 60/40 for cold weather areas.
▪ Minimum coolant concentration is 40/60 for warm weather areas.

Filling and Bleeding without RADIATOR REFILLER

NOTICE:
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. Failure to
follow these instructions may result in damage to the cooling system.
To maintain the integrity of the coolant and the cooling system:

• add Motorcraft Premium Gold Engine Coolant with Bittering Agent. Always fill the cooling system with the same type of coolant that was
drained from the system. Do not mix coolant types.
• do not add orange-colored Motorcraft Specialty Orange Engine Coolant with Bittering Agent (US). Mixing coolants may degrade the coolant's
corrosion protection.
• do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from
overheating or freezing.

1. NOTICE:
With the engine cold, fill vehicles to within the cold fill range shown on the degas bottle. This fill level will allow for coolant expansion.
Overfilling the degas bottle may result in damage to the pressure cap, which can cause the engine to overheat.

Fill the engine cooling system via the degas bottle until coolant level is between the coolant fill level marks.
• Recommended coolant concentration is 50/50 ethylene glycol to distilled water.
▪ Maximum coolant concentration is 60/40 for cold weather areas.
▪ Minimum coolant concentration is 40/60 for warm weather areas.
2. Run the engine at 2,000 rpm for 5 minutes, until it reaches operating temperature.
3. Turn off the engine and allow the cooling system to cool.
4. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the COOLANT FILL LEVEL marks.
5. NOTE:
If the air discharge remains cool and the engine coolant temperature gauge does not move, the engine coolant level is low in the engine and must be
filled. Stop the engine, allow to cool and fill the cooling system as described.

Start the engine and allow it to idle until normal operating temperature is reached. Hot air should discharge from the A/C vents with the climate
control setting to full heat. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the
upper radiator hose should feel hot to the touch.
6. Repeat Steps 3 through 5 until the degas bottle is at the correct level.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

Cooling Fan Stator — 6.0L Diesel ....................................................................................................................................... 303-03-2

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303-03-2 Engine Cooling 303-03-2

Cooling Fan Stator — 6.0L Diesel

Removal and Installation
1. Remove the cooling fan. For additional information, refer to Cooling Fan — 6.0L Diesel in this section.
2. Remove the 4 bolts and cooling fan stator.
• To install, tighten to 40 Nm (30 lb-ft).

3. To install, reverse the removal procedure.

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

DESCRIPTION AND OPERATION

Engine Cooling ................................................................................................................................................................... 303-03-2

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303-03-2 Engine Cooling 303-03-2

DESCRIPTION AND OPERATION

Engine Cooling

NOTICE:
Always fill the cooling system with the same type of coolant that is present in the system. Do not mix coolant types.

The cooling system components are the:

• Block heater
• Fan blade
• Fan clutch
• Fan shroud
• Radiator
• Degas bottle
• Pressure relief cap
• Radiator draincock
• Coolant pump
• Coolant thermostat
• Oil filter adapter
• Upper radiator hose
• Lower radiator hose
• Degas bottle supply hose
• Fan stator — 6.0L
• Engine appearance cover — 6.0L

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 distilled water.

To maintain the integrity of the coolant and the cooling system:

• NOTICE:
With the engine cold, fill vehicles with a yellow fill level decal to within the yellow cold fill range shown on the decal. If the decal is missing, fill
the degas bottle only to the molded line. The correct fill level on these vehicles is between the molded line and 15 mm (0.59 in) below the line.
These fill levels will allow for coolant expansion. Overfilling the degas bottle may result in damage to the pressure cap, which can cause the
engine to overheat.

NOTE:
If cooling system stop leak pellets are used, Motorcraft® Premium Gold Engine Coolant may darken from yellow to golden tan.

Add Motorcraft® Premium Gold Engine Coolant with Bittering Agent (US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)
meeting Ford specification WSS-M97B51-A1. Do not mix coolant types.
• Do not add/mix orange-colored Motorcraft® Specialty Orange Engine Coolant with Bittering Agent (US) Motorcraft® Extended Life Engine Coolant
(Canada) VC-3 (US); CXC-209 (Canada); or equivalent, meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant's
corrosion protection.
• Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from
overheating or freezing.
• Do not mix with recycled coolant unless it meets with the requirements of Ford specification WSS-M97B51-A1. Not all coolant recycling processes
meet these Ford specifications. Use of such coolants may harm the engine and cooling system components. Do not mix coolant types.

NOTICE:
Inadequate concentration of Motorcraft® Diesel Cooling System Additive may result in major corrosive damage to the engine cooling system
components. An excessive amount of additive may cause formation of gels that may cause coolant flow restriction, plugging of passages and
overheating.

For vehicles equipped with a diesel engine, use Motorcraft® Diesel Cooling System Additive as specified in the diesel engine coolant test. Motorcraft®
Diesel Cooling System Additive provides additional long-term protection against cavitation erosion and corrosion beyond that provided by the engine
coolant. Check the nitrite level and freeze protection as recommended in the maintenance schedule and maintain the correct level of Motorcraft® Diesel
Cooling System Additive in the cooling system. Refer to Coolant Test — Diesel Engine in this section.

Coolant Flow Diagram, 5.4L 3V

NOTE:

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303-03-3 Engine Cooling 303-03-3
DESCRIPTION AND OPERATION (Continued)
Black arrows indicate hot, White arrows indicate cold.

Item Part Number Description

1 8005 Radiator assembly
2 8B273 Lower radiator hose assembly
3 6A642 Oil cooler assembly
4 6B84 Oil filter adaptor
5 6010 Cylinder block
6 6083 LH Cylinder head gasket
7 6050 LH Cylinder head
8 18471 Heater assembly
9 18K580 Heater outlet hose assembly
10 8594 Thermostat housing
11 8C369 Coolant crossover assembly
12 18663 Heater coolant outlet tube
13 18K579 Heater inlet hose assembly
14 8B274 Upper radiator hose assembly
15 8A080 Degas bottle
16 6049 RH Cylinder head
17 8C351 Degas bottle outlet hose
18 8501 Coolant pump
19 8W005 Degas bottle inlet hose

Coolant Flow Diagram, 6.8L 3V

NOTE:
Black arrows indicate hot, White arrows indicate cold.

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DESCRIPTION AND OPERATION (Continued)

Item Part Number Description

1 8005 Radiator assembly
2 8B273 Lower radiator hose assembly
3 6A642 Oil cooler assembly
4 6884 Oil filter adaptor
5 8C351 Degas bottle outlet hose
6 8A080 Degas bottle
7 8W005 Degas bottle inlet hose
8 6010 Cylinder block
9 6083 LH Cylinder head gasket
10 6050 LH Cylinder head
11 18471 Heater assembly
12 18663 Heater coolant outlet tube
13 18K580 Heater outlet hose assembly
14 8594 Thermostat housing
15 18K579 Heater inlet hose assembly
16 8C369 Coolant crossover assembly
17 6049 RH Cylinder head
18 8B274 Upper radiator hose assembly
19 8501 Coolant pump

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SECTION 303-03 Engine Cooling

CONTENTS PAGE

GENERAL PROCEDURES
Cooling System Flushing — Gasoline Engines ................................................................................................................... 303-03-2

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303-03-2 Engine Cooling 303-03-2

GENERAL PROCEDURES
Cooling System Flushing — Gasoline Engines

Material
Item Specification
Premium Cooling System Flush ESR-M14P7-A
VC-1

1.
WARNING:
To avoid personal injury, do not unscrew the coolant pressure relief cap while the engine is operating or hot. The cooling system is under
pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly.

Once pressure is released, remove the pressure relief cap.

Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Remove the coolant thermostat.
3. Install the coolant hose connection without the coolant thermostat.
4. NOTE:
Refer to the cooling system flusher manufacturer's operating instructions for specific vehicle hook-up.

Use an appropriate cooling system flusher to flush the engine and radiator.
Use Premium Cooling System Flush or equivalent.
5. Install the coolant thermostat. For additional information, refer to Thermostat — 5.4L, 6.8L in this section.
6. Backflush the heater core if necessary. For additional information, refer to Heater Core Backflushing in this section.
7. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.

2007 F-250, 350, 450, 550 Super Duty, 6/2006

303-03-i Engine Cooling 303-03-i

SECTION 303-03 Engine Cooling

CONTENTS PAGE

Radiator and Cooling Fan — Exploded View, Gasoline Engines ........................................................................................ 303-03-2

2007 F-250, 350, 450, 550 Super Duty, 6/2006

303-03-2 Engine Cooling 303-03-2

Radiator and Cooling Fan — Exploded View, Gasoline Engines

Item Part Number Description

1 15161 Upper radiator hose clamp
2 8B274 Upper radiator hose
3 W527352 Degas bottle hose clamp
4 8W005 Degas bottle hose
5 8A616 Cooling fan clutch
6 N807658 Radiator shroud bolts (2 required)
7 8146 Radiator shroud
8 8600 Cooling fan
9 57632 Cooling fan-to-clutch bolt (4 required)

2007 F-250, 350, 450, 550 Super Duty, 6/2006

303-03-3 Engine Cooling 303-03-3
(Continued)

Item Part Number Description

10 15161 Lower radiator hose clamp
11 8B273 Lower radiator hose
12 7A031 Transmission cooler lines
13 n606676 Radiator support bracket bolts (4 required)
14 8B359 Radiator support brackets (2 required)
15 8B204 Upper radiator insulators (2 required)
16 8005 Radiator
17 8B204 Lower radiator insulator (2 required)

1. For additional information, refer to the procedures in this section.

2007 F-250, 350, 450, 550 Super Duty, 6/2006

303-03-i Engine Cooling 303-03-i

SECTION 303-03 Engine Cooling

CONTENTS PAGE

Coolant Pump — Gasoline Engines .................................................................................................................................... 303-03-2

2007 F-250, 350, 450, 550 Super Duty, 6/2006

303-03-2 Engine Cooling 303-03-2

Coolant Pump — Gasoline Engines

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31

Item Part Number Description

1 N806282 Coolant pump pulley bolts (4 required)
2 8A528 Coolant pump pulley
3 N808794 Coolant pump bolt (4 required)
4 8501 Coolant pump
5 391108 Coolant pump O-ring seal

Removal and Installation

1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
2. Remove the cooling fan. For additional information, refer to Cooling Fan — Blade, Clutch and Shroud, 5.4L, 6.8L in this section.
3. Remove the accessory drive belt. For additional information, refer to Section 303-05.
4. Remove the 4 bolts and the coolant pump pulley.
• To install, tighten to 25 Nm (18 lb-ft).
5. Remove the 4 bolts and the coolant pump. Discard the O-ring seal.
• Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep.
• Install a new O-ring seal. Lubricate the O-ring seal with clean engine coolant prior to installation.
• To install, tighten to 25 Nm (18 lb-ft).
6. To install, reverse the removal procedure.

2007 F-250, 350, 450, 550 Super Duty, 6/2006

2007 Ford F-250 SUPER DUTY
Submodel: LARIAT | Engine Type: V8 | Liters: 5.4
Fuel Delivery: FI | Fuel: GAS

SECTION 303-03:
Engine Cooling

SPECIFICATIONS
DESCRIPTION AND OPERATION
Engine Cooling
DIAGNOSIS AND TESTING
Engine Cooling
Principles of Operation
Inspection and Verification
PCM DTC Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: Loss of Coolant
Pinpoint Test B: The Engine Overheats
Pinpoint Test C: The Engine Does Not Reach Normal Operating Temperature
Component Tests
Pressure Test — Degas Bottle Systems
Pressure Test — Coolant Expansion Tank Systems
Cap
Thermostat
Radiator Leak Test, Removed From Vehicle
Fan Clutch Test
GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding
Draining
Filling and Bleeding with RADKITPLUS
Filling and Bleeding without RADKITPLUS
Cooling System Flushing
Heater Core Backflushing
REMOVAL AND INSTALLATION
Block Heater — Gasoline Engines
Block Heater — 6.0L Diesel
Bypass Tube
Thermostat — 5.4L, 6.8L
Thermostat — 6.0L Diesel
Coolant Pump — Gasoline Engines
Coolant Pump — 6.0L Diesel
Radiator and Cooling Fan — Exploded View, Gasoline Engines
Cooling Fan — Blade, Clutch and Shroud, 5.4L, 6.8L
Radiator — Gasoline Engines
Radiator and Cooling Fan — Exploded View, Diesel Engines
Cooling Fan Shroud — 6.0L Diesel
Cooling Fan — 6.0L Diesel
Cooling Fan Stator — 6.0L Diesel
Radiator — Diesel Engines
Degas Bottle — 5.4L, 6.8L
Degas Bottle — 6.0L Diesel
303-03-i Engine Cooling 303-03-i

SECTION 303-03 Engine Cooling

CONTENTS PAGE

Block Heater — 6.0L Diesel ................................................................................................................................................. 303-03-2

2007 F-250, 350, 450, 550 Super Duty, 6/2006

303-03-2 Engine Cooling 303-03-2

Block Heater — 6.0L Diesel

Item Part Number Description

1 — Block heater electrical connector (part of 6B018)
2 6A051 Block heater
3 — Block heater O-ring seal (part of 6A051)

Removal and Installation

1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.
3. Disconnect the block heater electrical connector.
4. Remove the block heater and discard the O-ring seal.
• To install, tighten to 41 Nm (30 lb-ft).
• Install a new O-ring seal.
5. To install, reverse the removal procedure.

2007 F-250, 350, 450, 550 Super Duty, 6/2006