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303-03C-1 Engine Cooling 303-03C-1 SECTION 303-03C Engine Cooling VEHICLE APPLICATION: 2011.50 Ranger CONTENTS PAGE SPECIFICATIONS Specifications 303-03C-2 DESCRIPTION AND OPERATION Engine Cooling 303-03C-3 GENERAL PROCEDURES Cooling System Draining, Filling and Bleeding (24 122 0) Draining Filling Bleeding Cooling System Draining and Vacuum Filling Draining Evacuating and Filling 303-03C-5 303-03C-5 303-03C-5 303-03C-5 303-03C-7 303-03C-7 303-03C-8 REMOVAL AND INSTALLATION Thermostat (24 454 0) Coolant Pump (24 404 0) Radiator (24 254 0) Cooling Fan Motor and Shroud (24 222 0) Coolant Outlet Connector 303-03C-10 303-03C-11 303-03C-12 303-03C-14 303-03C-16 Engine Cooling 303-03C-2 303-03C-2 SPECIFICATIONS Lubricants, Fluids, Sealers and Adhesives Item Specification Motorcraft Super Plus Antifreeze Antifreeze Specific Gravity (providing no other additive is in coolant) 1.068 at +15°C WSS-M97B44–D Approximate percentage of AntiFreeze (by volume) Remains Fluid to Solidifies at 50% –30°C (–22°F) –35°C (–31°F) Cooling System Refill Capacity - Vehicles with 2.5L Duratec-HE (MI4) engine Description Liters Cooling system and heater 11.0 Cooling System Pressure Specification Description Pressure kpa (psi) Radiator pressure test 138 (20) Coolant expansion tank cap release pressure 135 to 155 (19 to 22) 2011.50 Ranger G1272448en Engine Cooling 303-03C-3 303-03C-3 DESCRIPTION AND OPERATION Engine Cooling Item Description Radiator Cooling fan motor and shroud Coolant expansion tank Coolant pump Thermostat Coolant pump pulley 2011.50 Ranger CAUTION: If the coolant concentration is insufficient, low temperature protection and corrosion resistance will be impaired NOTE: Providing the coolant has not been contaminated with other fluids or foreign material, the robust corrosion resistance properties of this coolant means that it can be reused after changing an aluminum cooling system component The concentration should always be checked and maintained within the specification G1272449en 303-03C-4 Engine Cooling 303-03C-4 DESCRIPTION AND OPERATION Coolant concentration should be checked through the neck of the coolant expansion tank with a hydrometer The acceptable range of specific gravity (sg) must be maintained The coolant used is an orange colored Motorcraft Super Plus 2000 engine coolant This is a non silicated organic acid technology (OAT) coolant that must not be mixed with other coolant types For cooling system top up, only use coolant which meets the correct specification 2011.50 Ranger G1272449en 303-03C-5 Engine Cooling 303-03C-5 GENERAL PROCEDURES Cooling System Draining, Filling and Bleeding(24 122 0) Draining Remove the radiator drain plug and drain the coolant WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth Release the cooling system pressure by slowly turning the coolant expansion tank cap between and turns Install the radiator drain plug Lower the vehicle Filling Refill the coolant to the expansion tank to maximum line (+15mm) Bleeding CAUTION: The fluid level must remain between the MAX and MIN marks Run the engine for minutes at idle rpm Install the coolant expansion tank cap Run the engine speed to 2500 RPM and maintain it for approximately 15 minutes Run the engine for 5minutes at idle rpm Switch the engine off Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Check the cooling system for leaks 2011.50 Ranger G1357172en 303-03C-6 Engine Cooling 303-03C-6 GENERAL PROCEDURES Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Torque: 30 Nm Lower the vehicle 10 Allow the engine to cool and maintain close to room temperature 11 Fill the coolant to the expansion tank max fill line, if required 2011.50 Ranger G1357172en 303-03C-7 Engine Cooling 303-03C-7 GENERAL PROCEDURES Cooling System Draining and Vacuum Filling General Equipment Cooling System Vacuum Tester and Refiller Fluid Container Draining WARNING: When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth NOTE: Always follow the manufacturer's instructions when handling the equipment WARNING: Be prepared to collect escaping fluid Use a suitable coolant hose to drain the coolant General Equipment: Fluid Container Loosen: turn(s) Refer to: Engine Cooling System Health and Safety Precautions (100-00 General Information, Description and Operation) Release the cooling system pressure by slowly turning the coolant expansion tank cap between and turns Install the radiator drain plug Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) 2011.50 Ranger G1357173en 303-03C-8 Engine Cooling 303-03C-8 GENERAL PROCEDURES Torque: 30 Nm Close the valve, install the coolant hose and place it into the fluid container General Equipment: Cooling System Vacuum Tester and Refiller Close the valve and connect the compressed air hose Evacuating and Filling • If the cooling system was completely drained, fill the fluid container with the full cooling system fill capacity plus 0.5L of additional coolant • If the cooling system was partially drained, fill the fluid container with the removed and spilled amount of coolant plus 1.0L of additional coolant When in doubt always use the full cooling system fill capacity plus 0.5L of additional coolant General Equipment: Cooling System Vacuum Tester and Refiller Open the valve until the specificied vacuum is achieved Remove the coolant expansion tank cap 2011.50 Ranger G1357173en 303-03C-9 Engine Cooling 303-03C-9 GENERAL PROCEDURES • Open the valve until the coolant reservoir fluid level is at the MAX mark General Equipment: Cooling System Vacuum Tester and Refiller • If no coolant is visible in the coolant expansion tank, add 2.0L of coolant to the fluid container and repeat the evacuating and filling procedure Install the coolant expansion tank cap 2011.50 Ranger G1357173en 303-03C-10 Engine Cooling 303-03C-10 REMOVAL AND INSTALLATION Thermostat(24 454 0) Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) NOTE: The gasket is to be reused unless damaged Torque: 10 Nm Installation To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) 2011.50 Ranger G1272450en 303-03C-11 Engine Cooling 303-03C-11 REMOVAL AND INSTALLATION Coolant Pump(24 404 0) Torque: 10 Nm Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Loosen: turn(s) Installation NOTE: Install all the bolts finger tight before final tightening To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) Refer to: Accessory Drive Belt (303-05 Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4, Removal and Installation) Torque: 20 Nm NOTE: Make sure that the mating faces are clean and free of foreign material 2011.50 Ranger G1272451en 303-03C-12 Engine Cooling 303-03C-12 REMOVAL AND INSTALLATION Radiator(24 254 0) Removal NOTE: Removal steps in this procedure may contain installation details Refer to: Cooling Fan Motor and Shroud (303-03 Engine Cooling, Removal and Installation) NOTE: Take extra care not to damage the A/C refrigerant filling pipe 2011.50 Ranger NOTE: Take extra care not to bend the radiator Torque: 20 Nm G1272453en 303-03C-13 Engine Cooling 303-03C-13 REMOVAL AND INSTALLATION Lift the A/C condenser off the supports and move the A/C condenser toward the front of the vehicle and securely strap the A/C condenser on the grill support Torque: Nm NOTE: Radiator insulators are to be reused unless damaged NOTE: Take extra care not to damage the radiator during removal Installation NOTE: Make sure that no components catch when installing the radiator To install, reverse the removal procedure 2011.50 Ranger G1272453en 303-03C-14 Engine Cooling 303-03C-14 REMOVAL AND INSTALLATION Cooling Fan Motor and Shroud(24 222 0) Removal NOTE: Removal steps in this procedure may contain installation details Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) Torque: 11 Nm 2011.50 Ranger G1272452en 303-03C-15 Engine Cooling 303-03C-15 REMOVAL AND INSTALLATION Installation To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) 2011.50 Ranger G1272452en 303-03C-16 Engine Cooling 303-03C-16 REMOVAL AND INSTALLATION Coolant Outlet Connector Removal NOTE: Removal steps in this procedure may contain installation details on both sides Drain the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) Refer to: Lifting (100-02 Jacking and Lifting, Description and Operation) Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation) Torque: 11 Nm Torque: 14 Nm 2011.50 Ranger G1355953en 303-03C-17 Engine Cooling 303-03C-17 REMOVAL AND INSTALLATION Torque: 10 Nm 11 Torque: 48 Nm 12 NOTE: Make sure that the mating faces are clean and free of foreign material NOTE: The O-ring seal is to be reused unless damaged 10 NOTE: Make sure that these components are installed to the noted removal position NOTE: The gasket is to be reused unless damaged Installation To install, reverse the removal procedure Bleed the cooling system Refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures) 2011.50 Ranger G1355953en