Ford has a service bulletin forthis issue
COOLING SYSTEM—3.0L VULCAN ENGINE ONLY— Article No.
VARIOUS COOLANT RELATED SYMPTOMS— 01-11-6
CONTAMINATED OR DISCOLORED COOLANT
FORD: 1996-1999 TAURUS
MERCURY: 1996-1999 SABLE
NOTE repairs were performed.
THIS ARTICLE DOES NOT APPLY TO GULF • 1996-97 3.0L Vulcan - If bypass kit was
COAST COUNTRY (GCC) VEHICLES EQUIPPED previously installed, then install new water pump
WITH ENGINE OIL COOLER. A SEPARATE TSB (1F1Z-8501-AA) and perform the entire
WILL BE RELEASED SOON FOR THESE SEDIMENT/CHEMICAL FLUSH and fill procedure.
APPLICATION. If bypass kit was NOT previously installed, Install
coolant bypass kit (F7DZ-8522-AB) OR ISSUE (METHONAL VEHICLES F8DZ-8522-CC), new
Some vehicles may exhibit cooling system water pump (1F1Z-8501-AA) and perform the
conditions such as: entire SEDIMENT/CHEMICAL FLUSH and fill
• Contaminated/corroded coolant procedures.
• Leaking/Cracked/Discolored Coolant Overflow • 1998 3.0L Vulcan - Install Coolant bypass kit
bottles (F8DZ-8522-BA) on vehicles built 9/1/1997 -
• Vibration or thumping from engine 1/23/1998. Install water pump (1F1Z-8501-AA) on
all 1998 models regardless of build date. Perform • Leaking heater core
the entire SEDIMENT/CHEMICAL FLUSH if
• Coolant overflow bypass kit was NOT previously installed. If
• High temperature gauge readings bypass was previously installed or vehicle is
• Fluctuating temperature gauge outside the coolant bypass build range the
CHEMICAL FLUSH and Fill procedure may be • Stuck Thermostat
sufficient.
• Heater hose leaks • 1999 3.0L Vulcan - Perform FLUSH AND FILL
• Leaking head gasket PROCEDURE AND CHEMICAL FLUSH ONLY.
• Lack of heat
SERVICE PROCEDURE
This may be caused by:
1. Perform normal diagnostics as outlined in the
• Coolant level that falls below the cold fill range Cooling System Symptom charts located in the
due to un-serviced leaks, improper fill after appropriate model year Workshop Manual.
service and lack of coolant level maintenance that Service as required.
may lead to cooling system overheat damage.
2. If not previously installed, install appropriate
NOTE Coolant By-Pass Kit. Refer to the Instruction
IT IS RECOMMENDED THAT THE COOLANT sheet included in the kit for details.
CAN BE SAFELY FILLED TO THE TOP OF THE
CLEAR PORTION OF THE BOTTLE (WHEN THE 3. Install water pump on 1996-98 models only.
ENGINE IS COLD) TO PROVIDE EXTRA Refer to Workshop manual, Section 03-01A for
RESERVE COOLANT. (FIGURE 11). replacement details.
• Bank to bank coolant flow imbalance on some 4. Perform the following flush and fill procedures if
1996-98 model year vehicles. coolant is discolored.
ACTION
Perform the following repairs based on model year
application. Check repair history to determine if prior
Copyright © 2001 Ford Motor Company PAGE 1
Article No. 01-11-6 Cont’d.
FLUSH AND FILL PROCEDURE RECOMMENDED 14. Remove lower radiator hose from radiator and
TOOLS discard clamp.
The tools shown in Figure 1 are referenced 15. Clean core plug bores in cylinder block with
throughout the technical Instruction to facilitate the sand paper drum (Fine 150-grit 1.5″ dia.).
flush procedures. Tools should be obtained locally. Ensure all Loctite and rust is removed from
core plug bore.
FLUSH AND FILL PROCEDURE
16. Lower vehicle.
NOTE
POSITION THE VEHICLE ON A HOIST WHERE A 17. Connect garden hose to heater return hose
GARDEN HOSE CAN BE USED AND COOLANT using adapter (Figure 4).
CAN BE DISCARDED.
18. Turn garden hose on full pressure.
WARNING
19. Flush engine/heater core for ten (10) minutes. COOLANT MAY BE HOT. REMOVE COOLANT
Water will drain out of core plug holes. PRESSURE RELIEF CAP.
20. Disconnect garden hose from heater return
1. Raise vehicle on hoist.
hose.
2. Remove splash shield.
21. Insert garden hose into upper radiator hose
3. Remove Radiator draincock and completely (Figure 5).
drain and discard coolant.
22. Flush radiator for two (2) minutes. Water will
4. Lower vehicle. drain out of lower radiator hose connection and
draincock.
5. Loosen alternator brace retaining nuts and
position brace away from heater return hose 23. Remove garden hose from upper radiator hose.
(Figure 2).
24. Insert garden hose into coolant recovery bottle
6. Turn Heater and Blower Switches to off. (Figure 6).
7. Disconnect heater return hose from water pump 25. Flush coolant recovery bottle for four (4)
and discard clamp. minutes. Water will drain out of lower radiator
hose.
8. FOR 96, 97 AND SOME 98 MODEL YEAR
VEHICLES PROCEED WITH THE SEDIMENT 26. Remove garden hose from coolant recovery
AND CHEMICAL FLUSH PROCEDURES. FOR bottle. Let cooling system completely drain
99 MODEL YEAR, COMPETE THE CHEMICAL before proceeding to next step.
FLUSH PROCEDURE ONLY.
27. Remove clamping pliers from coolant by-pass
SEDIMENT FLUSH PROCEDURE hose.
9. Disconnect upper radiator hose from thermostat 28. Install new screw clamp on upper radiator hose.
housing and discard clamp. Connect upper radiator hose to thermostat
housing and tighten clamp.
10. Using clamping pliers, clamp off coolant
by-pass hose at center of hose (Figure 3). 29. Raise and support vehicle.
11. Raise and support vehicle. 30. Lubricate O-rings of new engine core plugs
(-6C057-) with silicone dielectric grease
12. Remove engine block core plug located next to (WA-10).
the oil filter. On the opposite side of the engine
block, there are two core plugs; remove the 31. Install left and right bank front engine core
engine block core plug closest to the water plugs. Index dimples on the plugs to 12 o’clock
pump. position. (Figure 7).
13. Remove lower radiator support bracket that NOTE
covers lower radiator hose. DO NOT OVER TORQUE.
PAGE 2
Article No. 01-11-6 Cont’d.
32. Tighten core plug retaining nuts to 3.2 N•m (28 46. Turn engine off and let chemical solution soak
lb-in). See Figure 7. Use 1/4″ drive, 8mm flex for a minimum of thirty (30) minutes, while
socket with a long extension is acceptable. engine cools.
Make sure plugs do not rotate when tightening
retaining nut. WARNING
COOLANT MAY BE HOT. REMOVE COOLANT
33. Install new screw clamp on lower radiator hose. PRESSURE RELIEF CAP.
Connect lower radiator hose to radiator and
tighten clamp. 47. Partially raise vehicle.
34. Install lower radiator support bracket. WARNING
PROCEED TO STEP 36 and continue. WARNING WEAR RUBBER GLOVES FOR THIS
STEP. CHEMICAL CLEANER MAY CAUSE SKIN
CHEMICAL FLUSH PROCEDURE IRRITATION.
WARNING 48. Remove radiator draincock.
WEAR RUBBER GLOVES DURING THIS STEP.
CHEMICAL CLEANER MAY CAUSE SKIN 49. Completely drain chemical solution and discard.
IRRITATION. 50. Lower vehicle.
35. Partially raise vehicle. 51. Disconnect heater return hose from water pump
36. Install radiator draincock. fitting (Figure 9).
37. Lower vehicle. 52. Install a 3/4″ I.D. rubber cap on the water
pump heater hose fitting (Figure 9).
38. DO NOT add chemical cleaner to the coolant
recovery bottle. Using a funnel, slowly add one 53. Disconnect and plug radiator overflow hose
(1) bottle of chemical cleaner from coolant recovery bottle. Discard clamp
(F8AZ-19A503-AA) into the HEATER RETURN (Figure 10).
HOSE (Figure 8). 54. Attach a 4 foot section of 3/8″ vinyl hose to
NOTE overflow fitting on the coolant recovery bottle.
THE RECOMMENDED CHEMICAL CLEANER Let vinyl hose hang over fender (Figure 10).
MUST BE USED. 55. Install coolant pressure relief cap.
39. Connect and clamp the heater return hose to 56. Connect garden hose (water supply) to heater
the water pump fitting. return hose using 3/4″ adaptor.
40. Slowly fill cooling system with water. Squeeze 57. Turn garden hose on full pressure.
upper radiator hose to purge air from system as
water is added. Coolant level must be filled to 58. With engine off, flush engine for at least five
the top of the clear portion of the coolant minutes and until water is clear. Water will
recovery bottle to completely clean the coolant drain out of radiator draincock and the 4 foot
bottle. vinyl hose.
41. Start engine and raise RPM to 2000 RPM for 2 59. Turn garden hose off and remove pressure
minutes. Do not exceed 2500 RPM. relief cap from bottle.
42. Check cooling system for leaks. 60. Disconnect garden hose from heater hose. Let
cooling system completely drain before
43. Recheck coolant level. Add water, if necessary proceeding.
to bring level up to the top of the clear portion
of the bottle. 61. Raise vehicle.
44. Install coolant bottle pressure relief cap. 62. Install and tighten draincock.
45. Run engine at idle until upper radiator hose is 63. Install splash shield.
hot (when thermostat opens) approximately 12
minutes. 64. Lower vehicle.
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Article No. 01-11-6 Cont’d.
65. Remove rubber cap from the water pump. 77. CAUTION: If air discharge remains cool and
engine coolant temperature gauge does not
66. Install new screw clamp on heater return hose move, engine coolant level is low and must be
and reconnect to water pump. Tighten clamp. filled. Stop engine, allow to cool and fill cooling
67. Reattach and secure alternator brace. system to top of clear lower portion of coolant
recovery bottle.
68. Remove 3/8″ vinyl hose.
78. Start engine and allow it to idle until normal
69. Unplug radiator overflow hose and install new operating temperature is reached. Hot air
screw clamp. Reconnect radiator overflow hose should discharge from panel vents. The engine
to coolant recovery bottle and tighten clamp. coolant temperature gauge should maintain a
stabilized reading within the NORMAL range
70. Add one (1) bottle (16 oz) of heavy duty and upper radiator hose should feel hot to
cooling system additive (FW-16) to coolant touch.
recovery bottle.
79. Shut engine off and allow engine to
71. Add six (6) quarts of new coolant to coolant COMPLETELY COOL.
recovery bottle. Fill remainder of cooling system
with water to top of clear lower portion of 80. Check engine for coolant leaks.
coolant recovery bottle.
81. IF NECESSARY, ADD COOLANT UNTIL
72. Start engine and top off with water to top of LEVEL IS AT THE TOP OF THE CLEAR
clear lower portion of coolant recovery bottle PORTION OF THE COOLANT BOTTLE
(Figure 11). (FIGURE 11).
NOTE 82. INFORM CUSTOMER THE IMPORTANCE OF
THE NEXT STEP MUST BE DONE BEFORE MAINTAINING COOLANT LEVEL. IT’S
THERMOSTAT OPENS. RECOMMENDED THAT COOLANT CAN BE
SAFELY FILLED TO THE TOP OF THE
73. Raise engine RPM to 3000 RPM for 30 CLEAR PORTION OF THE COOLANT BOTTLE
seconds and check for foaming inside the WHEN THE ENGINE IS COLD. THIS
coolant recovery bottle. If foaming is present PROVIDES EXTRA RESERVE COOLANT.
the coolant by-pass restrictor has not been
installed. Turn off engine and install the coolant PART NUMBER PART NAME
by-pass restrictor (F7PE-8N030-AA) contained F8AZ-19A503-AA Chemical Cleaner
in 1996-1997 bypass kit (F7DZ-8522-AB). Refer FW-16 Coolant Conditioner
to coolant by-pass restrictor installation VC-4A Engine Coolant
procedure in the bypass kit instructions. F7DZ-8522-AB Coolant By-Pass Kit - 96-97
Taurus/Sable
74. Install coolant pressure relief cap. F8DZ-8522-BA Coolant By-Pass Kit - 98
Taurus/Sable
75. Select maximum heater temperature and blower F8DZ-8522-CC Coolant By-Pass Kit - 96-97 Methonal
motor speed settings. Position control to Taurus/Sable
discharge air from the instrument panel vents. 1F1Z-8501-AA Water Pump - 96-98 Taurus/Sable F8DZ-6C057-AA Core Plug
76. When vehicle reaches normal operating
temperature, verify hot air from panel vents and
a hot upper radiator hose.
PAGE 4
Article No. 01-11-6 Cont’d.
OTHER APPLICABLE ARTICLES: NONE 011106C Perform Chemical Flush 1.6 Hrs.
SUPERSEDES: 97-24-16, 99-6-8 And Fill Procedures
WARRANTY STATUS: Eligible Under The 1998-1999 3.0L MFI, 3.0L
Provisions Of Bumper To FFV
Bumper Warranty Coverage DEALER CODING
OPERATION DESCRIPTION TIME CONDITION
011106A Replace Water Pump 4.1 Hrs. BASIC PART NO. CODE
(Includes Time To Perform 8A080 49
Sediment And Chemical OASIS CODES: 204000, 204200, 206000, 208000,
Flush And Fill Procedures) 208100, 208999, 402000, 497000,
1996-1998 3.0L MFI, 3.0L 499000
FFV
011106B Replace Water Pump And 4.6 Hrs.
Install By-Pass Kit
(Includes Time To Perform
Sediment And Chemical
Flush And Fill Procedures)
1996-1998 3.0L MFI, 3.0L
FFV
Figure 1 - Article 01-11-6
PAGE 5
Article No. 01-11-6 Cont’d.
Figure 2 - Article 01-11-6 Figure 4 - Article 01-11-6
Figure 3 - Article 01-11-6 Figure 5 - Article 01-11-6
PAGE 6
Article No. 01-11-6 Cont’d.
Figure 6 - Article 01-11-6 Figure 8 - Article 01-11-6
Figure 7 - Article 01-11-6 Figure 9 - Article 01-11-6
PAGE 7
Article No. 01-11-6 Cont’d.
Figure 10 - Article 01-11-6
Figure 11 - Article 01-11-6
PAGE 8
Parts will not be direct shipped for this program. Order your parts requirements through normal order processing
channels as noted below:
PART NUMBER/DESCRIPTION/DEALER PRICE
F7DZ-8522-AA, Coolant By-Pass Kit
E2FZ-19549-B, Coolant (6 quarts required)
DEALER PRICE
F7DZ-8522-AA, $ 15.00 @ Dealer Net
E2FZ-19549-B, $ 1.15 @ Dealer Net (per quart, based on 55 gallon drum price)
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with
Policy Procedure Bulletin 4000.
CLAIMS PREPARATION
l Enter using DWE.
l Use code information shown below:
Program Code - 98B18
Labor Operation - See above
See Sections 5 and 6 of the ACESII manual for detailed instructions.
ATTACHMENT III
Owner Notification Program 98B18
COOLING SYSTEM INSPECTION AND FLUSHING
AFFECTED VEHICLES:
CERTAIN 1996-1997 MODEL YEAR TAURUS AND SABLE VEHICLES EQUIPPED WITH 3.0L VULCAN ENGINES
INSPECTION
1. Open hood.
2. Check for presence of coolant by-pass hose shown in Figure 1.
l If coolant by-pass hose is present, no service action is required. Return vehicle to customer.
l If coolant by-pass is not present, proceed to service procedure.
ORDER TYPE EFFECTIVE DATE ORDER PROCESS
Stock Immediately Normal
Interim Immediately Normal
Emergency 31 days after launch Normal
Emergency First 30 days after launch Call 1-800-325-5621
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Figure 1
3. Check vehicle mileage.
l If vehicle mileage is 10,000 miles or more and heavy discoloration (rust) is noted in the coolant, the cooling
system must be flushed during the service procedure.
l If the vehicle mileage is under 10,000 miles, only a cooling system drain and fill is necessary.
SERVICE PROCEDURE
1. Raise vehicle.
2. Remove splash shield.
3. If vehicle mileage is 10,000 miles or more and heavy discoloration (rust) is in the coolant, completely drain and
discard cooling system fluid. Then flush cooling system with water as outlined in the 1996/97 Taurus/Sable
Service Manual, Section 03-03.
4. If the vehicle mileage is under 10,000 miles, completely drain and discard cooling system fluid.
5. Close radiator draincock.
6. Lower vehicle.
7. Remove clean air tube.
8. Remove coolant recovery hose from fitting shown in Figure 2.
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Figure 2
9. With suitable driver, shown in Figure 3, install restrictor insert (F7PE-8N030 -AA) as shown in Figure 4. Restrictor
insert must be installed flush to the shoulder on the coolant recovery fitting. It is acceptable if the restrictor insert is
loose in the fitting.
Figure 3
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Figure 4
10. Reinstall coolant recovery hose and clamp.
11. Remove heater return hose from the water pump and heater core return tube.
12. Remove fuel vapor hose clip from the stud on the dash panel. Install the new clip and fasten the nut, securing the
clip. Reinstall the fuel vapor hose clip. See Figure 5.
Figure 5
13. Install the coolant by -pass hose at the water pump and at the heater core return tube connection, located at the
dash panel. See Figure 6. Install the clamps at both connections inside "H" marking.
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Figure 6
14. Remove the heater supply hose from the lower intake manifold, See Figure 7, and leave it hanging loose.
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Figure 7
NOTE:
The "H" marking on the hose must be in the straight-up position.
15. Install the coolant by -pass hose to the lower intake manifold heater supply fitting and install clamp inside "H"
marking. Refer to Figure 6 and 7.
NOTE:
Check by -pass hose assembly for possible kinks or possible interference with the transmission dipstick and
ETA check valve.
16. Cut the heater supply hose approximately 8-1/2 inches from the original connection at the lower intake manifold.
Install existing clamp on the remaining heater supply hose. Install the heater supply hose to the "tee" on the
coolant by-pass. See Figure 7. Install hose clamp on "tee" connection.
17. Reinstall clean air tube.
18. Push (fasten) new coolant by-pass hose into the new clip on the dash panel. See Figure 8.
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Figure 8
19. Raise vehicle.
20. Install splash shield.
21. Lower vehicle.
CAUTION
Use extreme care to keep coolant mixture off of the drive belt and pulleys. If needed, remove drive belt
and rinse with clear water. Clean pulleys and install drive belt. Belt squeal and early drive belt fatigue will
occur otherwise.
22. Add new 50/50 coolant mixture into fill neck on coolant recovery bottle until coolant reaches top of cold fill range
mark on bottle.
23. Install pressure relief cap on coolant recovery bottle.
24. Select maximum heater temperature and blower motor speed settings. Position control to discharge air at A/C
vents in the instrument panel.
25. Start engine and allow to idle. While engine is idling, feel for hot air at A/C vents.
CAUTION
If air discharge remains cool and engine coolant temperature gauge does not move, engine coolant level
is low in engine and must be filled. Stop engine, allow to cool and fill cooling system as described.
26. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from A/C
vents. The engine coolant temperature gauge should maintain a stabilized reading to within the NORMAL range
and the upper radiator hose should feel hot to the touch.
27. Shut engine off and allow to cool.
28. Check engine for coolant leaks.
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