Ford Falcon. Manual — part 168

303-01c-93

Engine — V8 (4V)

303-01c-93

INSTALLATION (Continued)

37. Connect the alternator electrical connectors.

42. Install the surge tank hose to the radiator.

1. Release the clamp.

2. Slide the hose onto the radiator fitting.

38. Connect battery and alternator cables to RH relay

box.

39. Install the accessory drive belt. For additional

43. Connect the lower radiator hose and the upper

information, refer to Section 303-05.

radiator hose.

40. Install the intake manifold. For additional

44. Connect the transmission fluid cooler fittings.

information, refer to Intake Manifold—Upper in

1. Connect the lower transmission fluid cooler

this section.

fitting.

41. Install the radiator.

2. Connect the upper transmission fluid cooler

1. Install the radiator mounting insulators.

fitting.

2. Position the radiator on the radiator mounting

NOTE: To avoid disturbing the transmission

insulators.

oil cooler fittings, use a support hammer when

tightening fuel lines.

3. Position the brackets.

4. Install the bolts.

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303-01c-94

Engine — V8 (4V)

303-01c-94

INSTALLATION (Continued)

45. Install the fan shroud.

1. Install the fan blade and fan shroud, as a unit,

in the vehicle.

2. Install the screws.

46. Recharge the A/C system. For additional

information, refer to Section 412-00.

47. Fill the engine with oil.
48. Fill the engine cooling system. For additional

information, refer to Section 303-03.

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303-03-1 Engine

Cooling 303-03-1

SECTION : 303-03 Engine Cooling

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-2

DESCRIPTION AND OPERATION

Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-03-3

Radiator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-3

Electric

Fans

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-3

Water

Pump

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-03-3

Cooling

System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-3

Cooling

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-3

DIAGNOSIS AND TESTING

Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-03-5

Inspection and Verification . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-5

Symptom

Chart

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-5

Tests

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-6

Pressure

Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-8

Supply Tank Cap Pressure Test . . . . . . . . . . . . . . . . . . . . . . ..303-03-8

Thermostat

Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-8

Coolant

System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-03-8

Cooling Fan Self Test - All Models . . . . . . . . . . . . . . . . . . . . . ..303-03-8

GENERAL PROCEDURES

Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-03-9

Cooling Color Inspection . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-9

Adjusting Anti — Freeze Protection Level . . . . . . . . . . . . . . . . . . ..303-03-10

Anti — Freeze Replacement . . . . . . . . . . . . . . . . . . . . . . . ...303-03-10

Draining and Filling the Cooling System . . . . . . . . . . . . . . . . . . . .303-03-10

Radiator Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-10

REMOVAL AND INSTALLATION

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-03-12

Thermostat Housing — 8 Cylinder . . . . . . . . . . . . . . . . . . . . . ..303-03-12

Thermostat Housing — 6 Cylinder . . . . . . . . . . . . . . . . . . . . . ..303-03-12

Water Pump — 6 Cylinder . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-13

Water Pump — V8 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-14

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-03-14

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-03-16

Radiator Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-03-16

Coolant Supply Tank . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-03-16

303-03-2 Engine

Cooling 303-03-2

SPECIFICATIONS

General Specifications

Specific

Approximate

Remains

Solidfies at

Gravity

% of

Fluid to (C

°)

(C

°)

Description

Specification

Anti-Freeze

Fan Speeds

(by volume)

Passenger Side

1400, 2300 RPM @

1.050

30

-16

-39

12.0V

1.042

25

-13

-29

Driver Side

1400, 2300 RPM @

1.034

20

-9

-19

12.0V

1.026

15

-7

-14

Fan Motor Rating

160 W

1.016

10

-4

-8

Coolant Capacities
6 Cylinder Engine

12.5 litres

Torque Specifications - 6 & 8 Cylinder

8 Cylinder Engine

15 litres

Description

Nm

Anti-Freeze

Water outlet housing

21

All Engines

Motorcraft R132/R133

Radiator support bracket

10

Radiator Cleaner

Radiator hose clamps

5

All Engines

Motorcraft R1-5

Transmission oil cooler tube nuts

20

Radiator Cap Pressure (Supply Tank)

Fan shroud asy screw to radiator

6

All Engines

120 kPa

Water pump I6

20

Thermostat

Water pump V8

25

6 Cylinder Starts to open 89

° - 93°C

Water pump pully V8

25

Fully open 103

° - 106°C

Minimum travel of

capsule from fully closed

position: 7.1 mm

8 Cylinder Starts to open 87

°C-91°C

Fully Open 105

°C

Coolant Additive

Level of

Additive

Volume Volume Service

Protection Specification

of

of

Interval

Additive Water

Anti-

MES-

33%

67%

3 Years

corrosion MN121-C

(5.3

(10.7

100,000

&

(Motorcraft

litre)

litre)

km

anti-

R1-52)

freeze to

minimum

temp. of

-16

°C

Anti-

MES-

50% (8 50% (8 4 Years

corrosion MN121-C

litre)

litre)

120,000

&

(Motorcraft

km

anti-

R1-52)

freeze to

minimum

temp. of

-37

°C

Anti-Freeze Concentration

Specific

Approximate

Remains

Solidfies at

Gravity

% of

Fluid to (C

°)

(C

°)

Anti-Freeze

(by volume)

1.080

50

-37

-58

1.065

40

-25

-45

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