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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