Ford Falcon. Manual — part 171
303-03-11 Engine
Cooling 303-03-11
GENERAL PROCEDURES (Continued)
Driving
1. Remove the radiator as described in the Radiator
removal in this section.
2. Use air pressure line to clear the debris then
wash by using a hose (pressure cleaning is too
aggressive) between radiator and condenser. Do
not point the nozzle near the radiator and
condenser fins as this may damage them.
3. Reinstall the radiator as described in the Radiator
removal in this section.
4. Top up the coolant and transmission oil per
specifications.
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303-03-12 Engine
Cooling 303-03-12
REMOVAL AND INSTALLATION
6. Refill and bleed the cooling system as previously
Thermostat
described in this section.
Removal and Installation
NOTE: On thermostats that have a bleeder valve,
the thermostat should be positioned with bleeder
1. Partially drain the engine coolant so that the
valve at the 12 o’clock position as viewed from
coolant level is below the thermostat. For
front of engine.
additional information refer to Cooling System
Draining Filling and Bleeding in this section.
Thermostat Housing — 8 Cylinder
2. Remove the two bolts and separate the water
outlet adapter from the thermostat housing and
Removal and Installation
slide (with hoses attached) to one side.
NOTE: The 5.4-3V V8 thermostat housing is located
6 Cylinder
at the coolant cross over manifold between the
cylinder heads.
1. Disconnect the battery. For additional information
refer to Electrical system section.
2. Remove the drive belt as previously described in
this section.
3. Remove the alternator. For additional information
refer to Electrical system section.
4. Drain the engine coolant as previously described
in this section.
5. Remove the Thermostat as previously described
in this section.
6. Remove the two bolts securing the coolant
manifold to the LHS cylinder head.
7. Remove the bolt securing the coolant manifold to
Item
Description
the RHS cylinder head.
1
Bolt
8. Remove the inlet manifold bolt clamping the
2
Housing
coolant manifold and loosen the adjacent inlet
3
Thermostat
manifold bolts to allow removal of coolant
4
Conn water outlet
manifold.
9. Clean and inspect the gasket.
8 Cylinder
10. Fitting a new gasket/s requires inlet manifold
removal. For additional information refer to Fuel
system section.
11. Clean and inspect the sealing surfaces. To install,
reverse the removal procedure.
12. Refill and bleed the cooling system as previously
described in this section.
NOTE: All hardware must be correctly installed
and torqued to specification.
Thermostat Housing — 6 Cylinder
Removal and Installation
1. Remove the thermostat. For additional
information, refer to Thermostat in this section.
Item
Description
2. Remove the bolt and clamp that holds the heater
1
Bolt
tube to the housing. Remove the bolt holding the
2
Thermostat
heater tube on the inlet manifold. Withdraw the
3
Housing
heater tube from the thermostat housing.
3. Remove the thermostat and the O-ring seal.
4. Clean and inspect the sealing surfaces.
5. To install reverse the removal procedure.
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303-03-13 Engine
Cooling 303-03-13
REMOVAL AND INSTALLATION (Continued)
3. Remove the two bolts and separate the
3. Remove the water pump from the cylinder block
thermostat housing from the cylinder head.
being careful not to damage the heater pipe. This
pipe is a slide fit with an ‘O’ ring seal.
Item
Description
1
Bolt
2
O-ring
3
Seal
4
Bolt
5
Housing
6
Thermostat
7
Conn Water outlet
4. Clean and inspect the sealing surfaces after
removing all traces of gasket material.
5. Fit a new gasket and O-ring.
6. To install, reverse the removal instructions.
7. Refill and bleed the cooling system as previously
4. If necessary, the water pump pulley can be
described in this section.
removed using 888-000.
Installation
Water Pump — 6 Cylinder
NOTE: If necessary, install the water pump pulley
Special Tool(s)
before installing the water pump, using 416-D001.
Installer Power Steering Pump
1. Clean the heater outlet pipe and the matching
Pulley (6 & 8 Cylinder)
opening in the water pump. Lubricate a new ‘O’
416-D001
ring seal and install on the heater pipe.
(A7005)
2. Clean the pump and cylinder block mating
surfaces and install a new gasket coated with
water resistant sealer.
3. Position the water pump on the cylinder block and
heater pipe. Install the bolts and lock washers.
Remover Power Steering Pump
Pulley (6 & 8 Cylinder) 888-000
4. Refit the lower radiator hose.
(A7185)
5. Install the drive belt, refer to Section 303-03a.
6. Fill the cooling system as described in Section
303-03a.
NOTE: All hardware must be correctly installed
and torqued to specification.
Removal
1. Drain the cooling system as described in Section
303-03a.
2. Remove the accessory drive belt.
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303-03-14 Engine
Cooling 303-03-14
REMOVAL AND INSTALLATION (Continued)
Water Pump — V8
CAUTION: Do not rotate the coolant pump
housing once installed in the engine. Damage the
Removal
O-Ring seal can occur, causing the coolant pump
1. Drain the engine coolant. For additional
to leak.
information, refer to General Procedures in this
NOTE: Install a new O-Ring seal and lubricate with
section.
the same clean engine coolant that is present in the
2. Loosen the coolant pump pulley bolts.
system. Do not mix coolant types.
Installation
1. To install, reverse the removal procedure.
Radiator
Removal
1. Drain the cooling system as described in General
Procedures Section. Disconnect the upper and
lower radiator hoses.
2. Disconnect the coolant supply hose from the side
of the radiator and the bleed hose from the top of
the radiator.
6 Cylinder
3. Remove the accessory drive belt. For additional
information, refer to Section 303-05.
4. Remove the bolts and the coolant pump pulley.
Item
Description
1
Hose assy. Upper
2
Hose assy. Bleed
5. Remove the four bolts and the coolant pump.
3
Hose to engine vent
6. If necessary wipe the coolant pump mounting
surface with a soft cloth.
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