Ford - Through - Workshop Manual - 2009 - 2009

ATTACHMENT III PAGE 1 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 CERTAIN 2007 THROUGH 2009 MODEL YEAR EDGE AND MKX VEHICLES — COOLING SYSTEM CORROSION Please review the NEW information on pages 9, 12, 17, 20, 22 and 25. A Critical Points Sheet (Attachment IV) and a video have been developed to further highlight some areas of the procedure that are important for successful cooling system flushing. OVERVIEW In some of the affected vehicles, cooling system corrosion may lead to contamination of the heater core. This contamination may, over time, lead to reduced heater performance. This service procedure is very extensive and detailed. Listed below are the sections of the service procedure along with highlights of important information. VERIFICATION • Measure temperature difference in the center vents • If greater than 15° ° F (8° C), proceed to the service procedure • If less than 15° F (8° C), follow normal WSM diagnosis EQUIPMENT LIST • Rotunda Tool Kit #303-1525 • Additional equipment needed WATER PUMP INLET TUBE • Replace the water pump inlet tube if the engine build date is on or before 4/1/2008 • Do NOT replace the water pump inlet tube, if the engine build date is on or after 4/2/2008 PRE-RINSE • Removes old coolant from the cooling system • Coolant MUST NOT mix with the VC-11 flush chemical VC-11 FLUSH • Removes contamination from the cooling system • VC-11 flush chemical temperature has to be between 135° F (57° C) and 150º F (65° C) for optimum cleaning performance POST-RINSE AND FILL • Removes VC-11 from the cooling system • VC-11 flush chemical MUST NOT mix with the new coolant • Necessary to use 5 gallons of distilled water for the final system fill CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 2 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 VERIFICATION VERIFY THE CUSTOMER CONCERN BY PERFORMING THE FOLLOWING HEATER PERFORMANCE EVALUATION. 1. Idle the engine at shop ambient temperature of 60° F (15° C) or higher, until the engine is fully warmed up. 2. Set the front climate temperature control to the hottest setting. 3. Set the mode to panel/vent (with all vents OPEN) and make sure the A/C is switched to the OFF position. Do NOT set the temperature control to the recirculation mode. 4. Set the blower to the highest speed. 5. Idle the engine for 5 minutes with the hood closed. 6. Measure the difference in the discharge air temperature between the left-center vent and the rightcenter vent as shown below. The difference should be less than 15° F (8° C) to meet the performance requirement. If the temperature DIFFERENCE IS LESS than 15° F (8° C), continue with normal Workshop Manual (WSM) diagnostic procedures. Do NOT proceed with this Service Procedure. If the temperature DIFFERENCE IS MORE than 15° F (8° C), continue to the Service Procedure. MEASURE THE TEMPERATURE DIFFERENCE BETWEEN THE LEFT-CENTER AND RIGHT-CENTER VENT 04X24A CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 3 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 SERVICE PROCEDURE NOTICE: ALL STEPS OF THIS SERVICE PROCEDURE MUST BE COMPLETED IN ORDER TO PROPERLY CLEAN THE COOLING SYSTEM. FAILURE TO FOLLOW THESE STEPS WILL COMPROMISE COOLANT PROTECTION CAPABILITY. NOTE: This procedure must be performed at an ambient temperature between 60° F (15° C) and 90° F (32° C) for proper utilization of the Motorcraft® Engine Cooling System Cleaner VC-11. NOTE: Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws. EQUIPMENT LIST NOTE: Before starting this service procedure, make sure that you have the equipment listed below. NOTE: The dealer bulletin contains the parts list for this service procedure (see Attachment II). Necessary equipment for the cooling system flush: 1. Rotunda Tool Kit #303-1525 2. Two large radiator hose pinch-off pliers (not supplied with the tool kit) 3. One clean 5 gallon bucket (not supplied with the tool kit) 4. An infrared thermometer or equivalent (not supplied with the tool kit) 5. Safety equipment (eye protection and chemical gloves, not supplied with the tool kit) 6. AirLift Cooling Tester UVU-550000 (not shown, formerly Radkit Plus) 7. Shop water supply hose (not shown) 8. Radiator drain pan (not shown) NOT SUPPLIED WITH TOOL KIT ROTUNDA TOOL KIT 303-1525 BUCKET PUMP FILL HOSE WITH NIPPLE SUCTION HOSE WITH NIPPLE PLUG CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 WATER VALVE DRAIN HOSE ATTACHMENT III PAGE 4 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 WATER PUMP INLET TUBE NOTE: Dispose of old coolant in accordance with local, state and federal laws. NOTE: On some of the affected vehicles, the water pump inlet tube is painted on the inside surface. The flushing chemicals will remove the paint and contaminate the cooling system and components. 1. Place a drain pan under the radiator drain valve and completely drain the cooling system through the radiator drain (degas bottle cap should be loose for proper draining). 2. Remove the air cleaner as an assembly. • Disconnect the mass air flow (MAF) sensor electrical connector. • Loosen the clamp and disconnect the air cleaner assembly outlet pipe from the air cleaner assembly. • Remove the air cleaner assembly bolts. • Separate the 2 air cleaner assembly feet from the rubber grommets. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 5 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 3. NOTE: The engine build date is on the engine code label, located on the RH cam cover or the front cover. The date is positioned in the center of the label in a date/month/year sequence. Locate and check the engine build date. See Figure 1. ENGINE CODE LABEL FRONT FIGURE 1 If the engine build date is ON or AFTER 4/2/2008, the water pump inlet tube does NOT need to be replaced. Proceed to Step 11. If the engine build date is ON or BEFORE 4/1/2008, it will be necessary to replace the water pump inlet tube. Proceed to Step 4. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 6 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 4. Remove the coolant hoses from the thermostat housing. See Figure 2. VENT HOSE WATER PUMP INLET TUBE THERMOSTAT HOUSING O-RING HEATER CORE OUTLET HOSE HEATER RETURN PORT HEATER CORE INLET HOSE THERMOSTAT HOUSING BOLT UPPER RADIATOR HOSE WATER PUMP INLET TUBE O-RING LOWER RADIATOR HOSE FIGURE 2 5. Remove the 3 thermostat housing bolts. 6. Separate the thermostat housing from the water pump inlet tube. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 THERMOSTAT HOUSING ATTACHMENT III PAGE 7 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 7. NOTE: The water pump inlet tube orientation can be determined by the length of the radius at the ends of the tube. The longer radius end is inserted into the water pump housing. See Figure 3. Remove the water pump inlet tube from the water pump housing using a slight twisting motion. The inlet tube must be replaced with a new inlet tube without paint on the interior surface of the tube. LONGER RADIUS END WATER PUMP INLET TUBE VIEW SHOWN WITH THE INTAKE MANIFOLD AND CYLINDER HEADS REMOVED FOR CLARITY FIGURE 3 8. Lubricate the new water pump inlet tube O-ring with clean engine coolant. 9. Install the new water pump inlet tube into the water pump housing. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 8 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 10. Install the thermostat housing. • Lubricate the thermostat housing O-ring with clean engine coolant. • Install the thermostat housing and 3 housing bolts. Tighten the bolts to 10 Nm (89 lb-in). • Install the coolant hoses to the thermostat housing EXCEPT for the heater core inlet and outlet hoses. See Figure 2. PRE-RINSE NOTE: The pinch-off pliers are used to control the direction of fluids in certain areas of the cooling system. They are also used for optimum cleaning and to prevent air from entering into the cooling system. 11. If the water pump inlet tube was NOT replaced, disconnect both the heater core inlet and outlet hoses from the thermostat housing. See Figure 4. HEATER CORE INLET HOSE (IB) HEATER CORE OUTLET HOSE (OB) HEATER RETURN PORT HEATER CORE INLET PORT FIGURE 4 12. Remove the 2 thermostat housing cover bolts and remove the thermostat. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 9 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 13. NOTE: Make sure that the upper radiator hose is correctly positioned into the locating bracket on the cooling fan shroud. If the upper radiator hose is above or below the locating bracket, air can be trapped in the hose and overheating will occur. See Figure 5. Position the flush tool kit plug into the thermostat housing to control the flow and install the O-ring, thermostat housing cover, and bolts. Tighten to 10 Nm (89 lb-in). See Figure 6. UPPER RADIATOR HOSE COOLING FAN SHROUD LOCATING BRACKET FIGURE 5 TOOL KIT PLUG FIGURE 6 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 10 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 14. NOTICE: The routing of the heater core inlet and outlet hoses, as well as the flush tool kit drain and pump hoses is critical to the flushing procedure. Incorrect routing will inhibit the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture from circulating and may cause an overheating condition. See Figure 7 for the cooling system flush hose routing. With the heater core inlet and outlet hoses off from step 11: • Connect the heater core inlet hose (IB - lower hose) to the heater return port (upper port) on the thermostat housing. • Connect the flush tool kit drain hose to the heater core inlet port on the thermostat housing. • Connect the flush tool kit hose-to-pump to the heater core outlet hose (OB) for the reverse flushing. FLUSH TOOL KIT DRAIN HOSE HEATER CORE INLET PORT HEATER CORE OUTLET HOSE (OB) HEATER CORE INLET HOSE (IB) HEATER RETURN PORT FLUSH TOOL KIT FILL HOSE-TO-PUMP (WITH NIPPLE) HOSE ROUTING FOR THE ENGINE COOLING SYSTEM FLUSH FIGURE 7 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 11 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 15. Route the flush tool kit drain and fill hoses under the thermostat housing and out of the engine compartment. Make sure that the hoses are NOT kinked. 16. NOTICE: To prevent any damage to the flush tool kit drain and fill hoses, place shop towels between the radiator shroud and the hoses. Position several shop towels between the hoses and the radiator shroud. See Figure 8. FRONT SHOP TOWELS TOOL KIT FILL HOSE TOOL KIT DRAIN HOSE FIGURE 8 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 12 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 17. Place the flush tool kit pump onto a tool cart in front of the vehicle. Connect the fill hose from the heater core outlet to the pump. See Figure 9. TOOL KIT FILL HOSE TOOL KIT PUMP TOOL KIT DRAIN HOSE TOOL KIT BUCKET TOOL KIT SUCTION HOSE SHOP BUCKET FIGURE 9 18. Position the flush tool kit 5 gallon bucket onto the tool cart along side the pump. See Figure 9. 19. Reinstall the air cleaner assembly and connect the MAF electrical connector. It is NOT necessary to secure the air cleaner assembly at this time. 20. NOTE: For measuring purposes, it is recommended to use a clean 5 gallon shop bucket. Place a separate empty 5 gallon shop bucket on the floor in front of the vehicle. See Figure 9. 21. Place the flush tool kit drain hose from the heater core inlet port on the thermostat housing into the empty bucket on the floor. See Figure 9. 22. Install the tool kit water valve onto the shop fresh water supply hose. Completely fill the cooling system through the degas bottle with fresh water until the water flows from the radiator drain. 23. Allow the radiator to completely drain. Close the radiator drain and install the degas bottle cap. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 13 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 24. NOTE: The pinch-off pliers are used to control the direction of fluids in certain areas of the cooling system. They are also used for optimum cleaning and to prevent air from entering into the cooling system. NOTE: If the vehicle is being lifted to install and remove the lower radiator hose pinch-off pliers, the flush tool kit pump must be secured onto the radiator shroud while lifting. Position and clamp the pinch-off pliers onto the upper radiator hose (see Figure 10) and the lower radiator hose (see Figure 11) as close to the radiator as possible. UPPER RADIATOR HOSE FRONT PINCH OFF PLIERS FIGURE 10 LOWER RADIATOR HOSE PINCH OFF PLIERS FRONT FIGURE 11 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 14 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 25. Place the flush tool kit suction hose from the pump into one of the small holes in the lid of the flush tool kit bucket that is along side of the pump. The hose MUST be kept a minimum of 2 inches from the bottom of the tool kit bucket. 26. Using the shop fresh water supply, fill the flush tool kit bucket with fresh water. Use the tool kit valve attached to the shop fresh water supply hose to maintain the water level in the tool kit bucket. 27. Connect a shop air supply to the pump, with the fresh water supply on, and maintain the water level in the tool kit bucket. 28. NOTE: Do NOT allow the tool kit supply bucket to become low or empty. This will introduce air into the cooling system and cause an overheating condition. With the fresh water supply on, monitor and maintain the water level in the tool kit bucket. 29. NOTE: Dispose of old coolant and flushing water contaminated with antifreeze in accordance with local, state and federal laws. Allow a minimum of 10 gallons of water to flush through the engine and out the drain hose into the shop bucket on the floor. It will be necessary to disconnect the shop air supply from the pump to eliminate the water flow from the drain hose while emptying the shop bucket. 30. After a minimum of 10 gallons of water has flushed through the engine, disconnect the shop air from the pump and turn off the fresh water supply. 31. Remove the tool kit bucket lid and empty the bucket. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 15 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 VC-11 FLUSH 32. NOTE: Both the suction and drain hoses MUST be kept a minimum of 2 inches from the bottom of the tool kit bucket. This will prevent any air from entering into the cooling system and causing an overheating condition. Reposition the drain hose from the 5 gallon bucket on the floor into one of the small holes in the lid of the flush tool kit bucket on the tool cart. See Figure 12. TOOL KIT DRAIN HOSE TOOL KIT SUCTION HOSE TOOL KIT FILL HOSE TOOL KIT PUMP FIGURE 12 33. Remove the pinch-off pliers from upper and lower radiator hoses. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 TOOL KIT BUCKET ATTACHMENT III PAGE 16 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 34. Install the pinch-off pliers onto the flush tool kit drain and suction hose closest to the flush tool kit bucket lid. See Figure 13. TOOL KIT DRAIN HOSE TOOL KIT SUCTION HOSE PINCH OFF PLIERS TOOL KIT BUCKET FIGURE 13 35. WARNING: THE USE OF SAFETY EQUIPMENT SUCH AS EYE PROTECTION AND CHEMICAL GLOVES IS REQUIRED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY. NOTICE: Bring the Motorcraft® Engine Cooling System Cleaner VC-11 to room temperature of 68° F (20° C) and shake well. Follow all of the Motorcraft® Engine Cooling System Cleaner VC-11 instructions and Precautions. Add 2 gallons of Motorcraft® Engine Cooling System Cleaner VC-11 to the flush tool kit bucket that is on the tool cart. Do not dilute the Motorcraft® Engine Cooling System Cleaner VC-11 in the flush tool kit bucket. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 17 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 36. NOTICE: It is necessary to use the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus) to remove any air from the cooling system. If air remains in the cooling system, the air will inhibit the circulation of the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture and will cause an overheating condition and possible damage to the engine. Rinse the shop bucket and fill with fresh water. Place the shop bucket so that the fill hose from the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus) will siphon the fresh water out of the bucket. Install the AirLift Cooling Tester UVU-550000 onto the degas bottle. Prime the AirLift Cooling Tester to remove any air from the tester (priming instructions are in the tester's literature). Fill the cooling system. 37. Remove the AirLift Cooling Tester UVU-550000 from the degas bottle and install the degas bottle cap. Make sure that the degas bottle is filled to 1 inch (25 mm) above the COLD FILL LEVEL. 38. Remove the pinch-off pliers from both hoses at the flush tool kit bucket. 39. Position one of the pinch-off pliers onto the upper radiator hose closest to the radiator. 40. Connect shop air supply to the tool kit pump. The pump will start to siphon the Motorcraft® Engine Cooling System Cleaner VC-11 from the bucket into the engine. 41. NOTICE: The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature MUST be between 135° F (57° C) AND 150° F (65° C). The temperature MUST exceed 135° F (57° C) for the required cleaning efficiency, and MUST NOT exceed 150° F (65° C) or damage to the engine may occur. If the engine or the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature EXCEEDS 150° F (65° C), the heater blower motor may be turned on to help cool down the engine cooling system. If the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture STILL EXCEEDS 150° F (65° C), the engine MUST be turned off and the key in the ON position to allow the heater blower motor to continue to operate. Allow the engine to cool down with the flush tool kit pump still circulating the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture. With the heater in the OFF position, start the engine and idle until the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature reaches 140° F (60° C). Monitor the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature using an infrared thermometer or equivalent in the flush tool kit bucket. 42. When the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature reaches 140° F (60° C), remove the pinch-off pliers from the upper radiator hose. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 18 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 43. Disconnect the A/C high pressure cut-off switch electrical connector. This will activate the engine cooling fans. It may take a few seconds until the cooling fans come on. See Figure 14. FRONT OF VEHICLE A/C HIGH PRESSURE CUT OFF SWITCH ELECTRICAL CONNECTOR FIGURE 14 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 19 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 44. THE NOTICES AND NOTES IN THIS STEP CONTAIN PERTINENT INFORMATION THAT MUST BE FOLLOWED AND ARE ESSENTIAL FOR THE CLEANING PROCESS. FAILURE TO FOLLOW THESE INSTRUCTIONS WILL INHIBIT THE CLEANING PROCESS AND MAY CAUSE DAMAGE TO THE ENGINE. NOTICE: Make sure that the radiator is NOT obstructed for maximum air flow. Any deflection of air may cause an overheating condition. NOTICE: The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature MUST NOT EXCEED 150° F (65° C) or damage to the engine may occur. If the Motorcraft® Engine Cooling System Cleaner VC-11/ water mixture temperature EXCEEDS 150° F (65° C), the heater blower motor can be turned ON to reduce the mixtures temperature. If the Motorcraft® Engine Cooling System Cleaner VC-11/ water mixture temperature STILL EXCEEDS 150° F (65° C), the engine MUST be turned OFF and the key left ON. The key MUST remain on for the operation of the heater blower motor to allow the engine to cool down. Continue the flush using the flush tool kit pump, circulating the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture through the cooling system. NOTICE: Do NOT allow the degas bottle to run low or empty. This will allow air to enter the cooling system and will cause an overheating condition and prevent the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture from circulating through the entire engine and cooling system. NOTE: The engine MUST idle for a MINIMUM of 2 hours with the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture circulating at a temperature between 135° F (57° C) and 150° F (65° C) to achieve required cleaning efficiency. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 20 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 Step 44 continued: NOTE: If the ambient temperature is 75° F (24° C) or less, it may be necessary to perform one of the following steps to maintain the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature above 135° F (57° C): • On vehicles equipped with a trailer tow package, it may be necessary to disconnect one of the vehicle’s cooling fans to decrease air flow through the radiator. See Figure 15. • On vehicles NOT equipped with trailer tow package, reconnect the A/C high pressure cut-off switch electrical connector. This will shut the fans off. See Figure 14. Allow the engine to idle for a MINIMUM of 2 hours. The Motorcraft® Engine Cooling System Cleaner VC-11/water mixture temperature MUST remain between 135° F (57° C) to 150° F (65° C). RH COOLING FAN ELECTRICAL CONNECTOR LH COOLING FAN ELECTRICAL CONNECTOR FIGURE 15 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 21 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 Step 44 continued: NOTE: To control any odor from the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture during the flush, install a shop exhaust hose into the lid of the tool kit bucket. To control any odor from the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture, it is recommended to install a shop exhaust hose into the lid of the tool kit bucket. See Figure 16. EXHAUST HOSE TOOL KIT SUCTION HOSE TOOL KIT FILL HOSE TOOL KIT DRAIN HOSE TOOL KIT BUCKET FIGURE 16 CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 22 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 45. EVERY half hour monitor the degas bottle for the correct level and measure the temperature in the tool kit bucket. DO NOT allow the Motorcraft® Engine Cooling System Cleaner VC-11/water mixture to get below the COLD FILL LEVEL. If necessary, release cooling system pressure by loosening the degas bottle cap slowly allowing air to escape and the degas bottle to fill to 1 inch (25 mm) above the COLD FILL LEVEL. 46. After the engine has idled for a MINIMUM of 2 hours, turn the engine OFF and leave the key in the ON position. Turn the heater blower motor ON and select the highest blower speed. 47. Continue flushing until the cooling system cleaner/water mixture reaches 120° F (49° C) with the heater blower motor on high. The temperature can be identified using an infrared thermometer or equivalent to monitor the mixture temperature in the flush tool kit bucket. 48. Disconnect shop air from the flush tool kit pump. 49. Turn the ignition key OFF. 50. Connect the A/C High Pressure switch and the cooling fan motor electrical connector (if disconnected). POST-RINSE AND FILL WARNING: THE USE OF SAFETY EQUIPMENT SUCH AS EYE PROTECTION AND CHEMICAL GLOVES IS REQUIRED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN SERIOUS PERSONAL INJURY. 51. NOTE: Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws. Empty and rinse the flush tool kit bucket, and then fill with fresh water. 52. Using caution, slowly open and remove the degas bottle cap. 53. Using caution, open the radiator drain. 54. NOTE: Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws. Allow the radiator to drain completely (degas bottle cap should be OFF). 55. Fill the degas bottle completely with fresh water and allow the radiator to drain. 56. Close the radiator drain and install the degas bottle cap. 57. Place an empty 5 gallon bucket on the floor in front of the vehicle. 58. Remove the flush tool kit drain hose from the flush tool kit bucket and place the drain hose into the empty shop bucket. 59. Install pinch-off pliers on the upper and lower radiator hoses as close to the radiator outlets as possible. See Figure 10 and Figure 11. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 23 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 60. NOTICE: Do NOT allow the flush tool kit bucket to run low or empty during the post-rinse and fill procedure. This will allow air to enter into the cooling system and cause an overheating condition. Keep the fresh water hose in the tool kit bucket and monitor the water level. Do not allow the bucket to run low or empty. 61. Connect air supply to the pump. 62. Allow a minimum of 10 gallons of water to flush through the engine and out the drain hose into the shop bucket on the floor. It will be necessary to disconnect the shop air supply from the pump to eliminate the water flow from the drain hose while emptying the shop bucket. 63. NOTE: Remove ONLY the pinch-off pliers from the lower radiator hose in this step. Remove the pinch-off pliers from the lower radiator hose. 64. NOTICE: Distilled water must be used for the final 5 gallon flush and fill. After flushing the system with a minimum of 10 gallons of fresh shop water, continue the flush using an additional 5 gallons of distilled water. 65. Remove the pinch-off pliers from the upper radiator hose. 66. Remove air supply from flush tool kit pump. 67. Disconnect the flush tool kit suction hose from the pump and remove the drain hose from the shop bucket. Move the tool cart with the bucket and pump aside. 68. Remove the degas bottle cap. 69. NOTE: Dispose of Motorcraft® Engine Cooling System Cleaner VC-11/water mixture in the same way as coolant in accordance with local, state and federal laws. Open the radiator drain and completely drain the radiator. 70. Close the radiator drain. 71. Remove the Air Cleaner Assembly. 72. NOTE: A black residue may be evident after the flushing procedure. This is a normal condition and requires NO action. Remove the heater core inlet hose from the heater return port on the thermostat housing. 73. Remove the drain hose from the heater core inlet port on the thermostat housing. 74. Remove the thermostat housing cover and remove the flush tool kit plug. 75. Install the thermostat and housing cover. Tighten the bolts to 10 Nm (89 lb-in). CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 24 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 76. Install the heater core inlet and outlet hoses onto the thermostat housing. See Figure 17. HEATER CORE INLET HOSE (IB) HEATER CORE OUTLET HOSE (OB) HEATER RETURN PORT HEATER CORE INLET PORT FIGURE 17 77. Install the Air Cleaner Assembly. • Install the air cleaner assembly into the rubber grommets. • Install the air cleaner assembly bolt and tighten to 9 Nm (80 lb-in). • Connect the air cleaner assembly outlet pipe and tighten the clamp to 5 Nm (44 lb-in). • Connect the MAF sensor electrical connector. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 25 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 78. NOTICE: The engine at this stage is filled with distilled water. The engine holds approximately 50% of the cooling system capacity. Add concentrated coolant, MOTORCRAFT® SPECIALTY GREEN ENGINE COOLANT, VC-10-A2 (US) or CVC-10-A (CANADA). Do NOT use the pre-diluted GENUINE MAZDA® EXTENDED LIFE COOLANT. Failure to follow these instructions may result in engine damage or cooling system concerns. Using the AirLift Cooling Tester UVU-550000 (formerly Radkit Plus), add 5.8 qts (5.5 L) for base models and 6.3 qts (6.0 L) for trailer tow models (vehicles equipped with an oil cooler) of 100% pure concentrated coolant. Use concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to the cooling system. Continue with the purge of air from the system until the coolant reaches 1 inch (25 mm) above the COLD FILL LEVEL. The recommended coolant concentration is 50/50 or -34° F (-36° C) using Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to distilled water, as measured with a hydrometer or equivalent. • Maximum coolant concentration is 60/40, -60° F (-51° C) for cold weather areas. • Minimum coolant concentration is 40/60, -20° F (-29° C) for warm weather areas. 79. Turn the heater to OFF. 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 MAY BE 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. 80. Start the engine and increase the engine speed to 3,500 rpm and hold for 30 seconds. 81. Turn the engine OFF and wait for 1 minute to purge any large air pockets from the cooling system. 82. NOTE: Add concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to 1 inch (25 mm) above the top of the COLD FILL LEVEL of the degas bottle. Check the engine coolant level in the degas bottle and if necessary, fill to 1 inch (25 mm) above the top of the COLD FILL LEVEL when warm or to the top of the COLD FILL LEVEL when cold using concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) OR CVC-10-A (Canada). 83. Start the engine and let idle until the engine reaches normal operating temperature and the thermostat is fully open. A fully open thermostat can be verified by the radiator cooling fan cycling on at least once. 84. With the engine ON, thermostat open and the cooling fans cycled at least once, increase the engine speed to 3,500 rpm and hold for 30 seconds. Then allow the engine to idle for 30 seconds. 85. Turn the engine OFF and wait for 1 minute. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014 ATTACHMENT III PAGE 26 OF 26 CUSTOMER SATISFACTION PROGRAM 09M04-S1 86. Repeat Steps 84 and 85 a total of 5 TIMES to remove any remaining air trapped in the system. 87. NOTE: Add concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada) to 1 inch (25 mm) above the top of the COLD FILL RANGE of the degas bottle. Check the engine coolant level in the degas bottle, and if necessary, fill to 1 inch (25 mm) above the top of the COLD FILL LEVEL with the engine warm or to the top of the COLD FILL LEVEL with the engine cold using concentrated coolant, Motorcraft® Specialty Green Engine Coolant VC-10-A2 (US) or CVC-10-A (Canada). 88. Make sure the degas bottle cap is installed to at least one audible “click.” 89. Overlay the new cooling system label onto the degas bottle cap that has been provided by service management. 90. Using the IDS, clear any codes that may have been set during the flush procedure. 91. Service management will provide the Customer Information Sheet to the customer for insertion into vehicle's Owner Guide. This Customer Information Sheet will remind the customer that a revised type of coolant has been installed in their vehicle and will need to be used from this point forward. CPR © 2010 FORD MOTOR COMPANY DEARBORN, MICHIGAN 48121 04/2010 SPX 09Z0014