239 1 1-1

PART 11-3RADIATOR, SUPPLY TANK ANDTHERMOSTATS 11-7

PART 11-5SPECIFICATIONS 11-10

PARTGENERAL COOLING SYSTEM SERVICE11-1

Section Page Section Page1 DiagnosisandTesting 11-1 3 CommonAdjustmentsandRepairs 1 1-32 Maintenance 11-2 4 CleaningandInspection 11-4

fl DIAGNOSIS AND TESTINGDIAGNOSIS Coolant loss may also be causedby the oil level dipstick could be an in-

internal leakagedue to a defective dication of internal leakage.Engine overheatingand slow en- cylinder headgasket, impropertight- Rust and scale that form in thegine warm-up are the two engine ening of the cylinder headbolts, or engine coolant passagesare carriedtroubles most commonly attributed a warped cylinder heador cylinder into the radiatorpassagesby thecirto the cooling system. block gasketsurface. culation of the coolant. This clogs

Loss of coolant, thermostatstuck Internal leakagecan be detected theradiatorpassagesandcausesover-in the closedposition, or the accu- by operatingthe engine at fast idle heating.Rust can be detectedby themulation of rust andscalein the sys- and looking for the formation of appearanceof the coolant. If thetern arethe main causesof overheat- bubblesin the radiator supply tank. coolanthasa rusty or muddy appearing. Coolant loss may be causedby Oil in the radiatorsupply tank may ance,rust is present.external leakageat the radiator, ra- indicate leakagein the engineblock A defective thermostat that rediator supplytank,waterpump,hose or a leak in the automatic transmis- mains open will causeslow engineconnections,heaterand core plugs. sion oil cooler.Water formation on warm-up.

DIAGNOSIS GUIDE

ENGINE OVERHEATS

Insufficient coolant. Cooling system passagesblockedBelt tension incorrect, by rust,scale,or otherforeignmatter.Radiatorfins obstructed. Water pump inoperative.Thermostatstuckclosed. Faulty fan drive clutch.

ENGINE FAILSTO REACH NORMALOPERATING TEMPERATURE

Thermostatstuck open, or of in- tive causing gaugeto indicate lowcorrectheat range. enginetemperature.

Temperaturesendingunit defec- Temperaturegaugedefective notindicating true enginetemperature.

LOSS OF COOLANT

Leaking radiator or radiator sup- headbolts.ply tank. Cylinder block core plugs leaking.

loose or damagedhose connec- Cracked cylinder head or block,tions. or warped cylinder head or block

Water pump leaking. gasketsurface.Cylinderheadgasketdefective. Radiatorpressurecap defectiveorImproper tightening of cylinder wrong type.

PART 11-1 PAGE PART 11-4 PAGEGENERAL COOLING SYSTEM SERVICE. .11-1 FAN DRIVE CLUTCH 11-9

PART 11-2WATER PUMP 11-5

GROUP 11-COOLING SYSTEM

TESTING

COOLING SYSTEMPRESSURE TEST

It is recommendedthat a coolingsystem pressuretest gauge be usedto properly testthe systemfor:

1. Blown or leakingcooling systemsealinggaskets.

2. Internal or external coolantleakage.

3. Pressurecap malfunction.Many typesof pressuregaugesare

available for use. Therefore, it isrecommendedthat the gaugemanufacturer’s instructions be followedwhen performing the test. Neverexceed the rated pressure indicated on the pressure cap whenperforming thepressuretest.

THERMOSTAT TESTS

Main Thermostat. Remove thethermostatandimmerseit in boilingwater. Replacethe thermostatif itdoes not open more than 1/4 inch.

If the problem being investigatedis insufficient heat, the thermostatshould be checkedfor leakage.Thismay be doneby holding the thermostat up to a lighted background.Light leakagearoundthe thermostatvalve thermostatat room temperature is unacceptableandthe thermostat should be replaced.It is possible,on some thermostats,that a slightleakageof light at oneor two loca

FIG. i-Power Booster Fan DriveClutch

tions on the perimeterof the valvemaybe detected.This should beconsiderednormal.

Cylinder Block Thermostats. Itis impossibleto check the operationof used cylinder block thermostatsdue to the distortion that occurs tothe units during their removal fromthe cylinder block. Do not attemptto repair them. Install new thermostats.

If new thermostatsaretested,fol

low the procedure for the mainthermostattest.

FAN DRIVE CLUTCH TEST

The recommendedtesting procedurefor the fan drive clutchFig. 1is as follows:

1. The viscosity of the siliconeoilwithin the drive chamberof the unitdirectly affects its drive characteristics. Therefore,the unit should notbe cold when tested.When ambientair temperaturesare below 65° F,operatethe engineat approximately1000rpm for 20 minutes.This shouldproduce the desired temperatureswithin the unit. However, regardlessof the ambient air temperature,the unit must be operated for atleast 5 minutes prior to testing.

2. Run the engine at approximately1000 rpm until normal operatingtemperatureis reached.This processcan be speededup by blocking offthe front of the radiator with cardboard.

3. Stop the engine and, using acloth to protect the hand, immediately check the effort required toturn the cooling fan. If considerableeffort is required,it can be assumedthat the coupling is operatingsatisfactorily. If very little effort is required to turn the fan, it is anindication that the coupling is notoperatingproperly and it should bereplaced.

o MAINTENANCECOOLANT

Correct coolant level is essentialfor maximum circulation and adequate cooling. In addition, for thecooling system to perform its function, it must receive proper care.This includes keeping the radiatorfins clean and a periodic inspectionof the cooling systemfor leakage.

Use care when removing theradiator cap to avoid injury fromescaping steam or hot water.

In production, the cooling systemis filled with a new long-life coolant.This coolant protectsto -35° F. Itwill not be necessaryto providespecialanti-freezeprotection exceptin areas where temperatures fallbelow this level. For year roundprotection from corrosion and overheating, and for low-temperatureprotection to -35° F, all coolantaddedshould be a mixture of 50%Ford Rotunda coolant concentrateand water. Use of greater than a

50-50 concentrate should beavoided to prevent possibleoverheating during warm weather. Donot mix permanent-type antifreezewith the methanol type.

In areaswhereprotectionto -35°F is not required, but someprotection is necessary,referto thecoolantmixture chart on the Ford Rotundacoolant can for the recommendedmixture proportions.

A standardethyleneglycoihydrometer can be used to check the protection level of the long-life coolant.

Referto Group 19 for the recommended cooling system drain interval.

DRAINING AND FILLINGTHE COOLING SYSTEM

1. Removethe radiator cap. Openthe radiator drain cock and removethe cylinder block drain plugs todrain the cooling system.

2. Clean or flush the cooling system, if required.

3. To fill the cooling system:Close the radiatordrain cock and

install thecylinder blockdrainplugs.Move the heatercontrol dial in

dicator clockwise to the "MAX"heat zone.

Fill the system with coolant to apoint one inch below the bottom ofthe supply tank filler neck.

Install thepressurecap andturn itclockwise until the first stop isreached.This will allow thecoolingsystem to vent entrapped air intothe atmosphere.Do not tighten thecap fully.

Operate the engine until normaloperating temperaturesare reached.After the initial fill, the coolantlevel drops due to the displacement of entrapped air. Add morecoolant to fill the supply tank to therequiredlevel. Tighten the pressurecap.

11-2

BI-METALSPRING

.7

240

241 PART 11-1-GENERAL COOLING SYSTEM SERVICE

4. Check the cooling system forleakage.Move theheatercontrol dial

FAN DRIVE BELTS fications. Also, check for misalignedpulleys. If the drive belts areworn

indicator to the "MIN" heat zone.Turn the ignition key to the "OFF"

If the fan drive belts are noisy,check the tension of the belts to

or frayed, replacethem following theproceduresin Part 11-1, Section 3.

position. make certain they are within speci

0 COMMON ADJUSTMENTS AND REPAIRS

ADJUSTMENTS

DRIVE BELTS

The belts must be properly adjustedat all times. Loosebelts causeimproperfan, waterpump andalternator operation. A belt that is tootight places a severestrain on thewater pump and the alternatorbearings.

Properly tensioned drive beltsminimize noiseandalso prolong theservicelife of the belt. Therefore,itis recommendedthat a belt tensiongaugebe used to check and adjustthe belt tension Fig. 2. Any beltthat hasoperatedfor a minimumof 10 minutes is considereda usedbelt, and when adjusted, it mustbe adjusted to the reset tensionshown in the specifications.

Belt Tension1. Remove the alternator splash

shield. Loosenthe alternatormounting bolts.

2. Loosen the alternator adjustingbracket bolt.

3. Install the belt tension gaugeon the fan drive belts. Move thealternatortowardor away from theengineuntil thespecifiedbelt tensionis obtai’ied. Remove the gauge.Tighten the alternator adjustingbracket bolt; then tighten the alternator mountingbolts.

Install thetension gaugeandcheckthe belt tension.

4. On a car with an air conditioner, remove the bolts securingthe compressor to the supportbracket that is attachedto the cylinder head. Loosen the bolts securingthe compressorto the compressormountingbracket.

Install the tension gauge on thecompressorclutch drive belt. Movethe compressortowardor awayfromthe engine until the specified belttension is obtained. Remove thegauge. Tighten the compressor tosupport bracket bolts. Install thetension gauge and check the belttension.

Too!-T631 8620-A Lor 81-33-73!

FIG. 2-FanAdjustment

5. Newbelts: Operate the enginefor ten minutes, then check thetensionof the belts to make certainthat they are within the resetspecifications. Adjust the belts, if required.

6. Install the alternator splashshield.

REPAIRS

FAN REPLACEMENT

Removal

1. Removethe ground cable fromthe battery.

2. Loosen the bolts securing thefan bladesand spacerto the waterpump pulley.Removethefan,spacer,and mounting bolts as a unit.

On a car with an air conditioner,loosen the bolts securing the fandrive clutch to the water pum]ppulley. Removethe fan, drive clutchandmounting bolts as a unit.

Installation

1. Position the spacer or driveclutch and fan on the water pumppulley and install the mountingbolts. Tighten the bolts.

2. Connectthe groundcableto thebattery.

FAN BELT REPLACEMENT

1. On a carwith an air conditioner,loosenthe air compressorto bracket

mounting bolts. Move the air compressortoward the engine and remove the compressordrive belt.

2. Remove the alternator splashshield. Loosenthe alternatormounting bolts andadjustingbracket bolts.

3. Move the alternatortoward theengine, and remoYe the fan drivebelts.

4. Install the fan drive belts onthe water pump pulley, crankshaftdamper and alternator pulley. Adjust the belt tension to specifications,andtighten the alternator mountingbolts and adjusting bracketbolts.

5. On acarwith an air conditioner,install the air compressordrive belton the water pump pulley and theair compressorclutch. Adjust thedrive belt tension to specifications,and tighten the air compressor tobracketmounting bolts.

6. Install the alternator splashshield.

RADIATOR HOSEREPLACEMENT

The radiator hoses should bereplaced whenever they becomecracked, rotted, or have a tendencyto collapse.

1. Drain the radiator. Loosen theclamps on eachend of the hose tobe removed. Slide the clamps intowardthe centerof the hose.

2. Slidethehosesoff the radiatorconnections. Remove the upperhose from the supply tank. Removethe lower hosefrom the waterpump.

3. Positionthe hoseclamps on thecenter of the radiator hoses. Install the hoses on the respectiveconnectionsand tighten the clampsfirmly. Make sure the clamps arelocated beyond the bead on theconnections.

4. Fill theradiatorto the requiredlevel with coolant. Start the engineand check for coolant leaks. Checkfor proper coolant level after theenginehasreachednormal operatingtemperature. Add coolant as required.

11-3

Drive Belt Tension

11-4 GROUP 11-COOLING SYSTEM

0 CLEANING AND INSPECTION

COOLING SYSTEMFLUSHING PROCEDURES

The design of the cooling systemrequires that specific steps be takento reverseflush the engine. Enginecooling system thermostatsopen inthe direction of coolant flow. Dueto this factor, it will be necessarytoremove all thermostatsto preventback-pressure.

The waterpumpmust beremovedto reach the cylinder block thermostat. Due to this condition, it ismore practical to reverseflush theengineseparatelyfrom the radiator.

REVERSE FLUSHINGPROCEDURE

1. Removethe water pump. Referto "Water Pump Removal" in Part11-2 for the proper procedure.

2. Remove the cylinder blockthermostats. Refer to "CylinderBlock Thermostats Removal" inPart 11-3 for the properprocedure.

3. Removethe coolantsupplytankand thermostat.Refer to "RadiatorSupply Tank and ThermostatRemoval" in Part 11-3 for the properprocedure.

4. Plug the coolant bypass tube.Connectawaterpressuregun attachment to the intake manifold as illustrated in Fig. 3.

5. Flush the cylinder block untilthesystemis clean.Removethepressuregun attachment.

6. Clean the gasket surfacesof thewaterpump, cylinder block, coolantsupply tank andthe intakemanifold.

WATER BY-PASS PLUG

WATER / - -DISCHARGE IOPENINGS / Pressure Gun

/__._-- *° Attachmer.t

WATER,CHARGE

OPENINGS

FIG. 3-Reverse FlushingProcedures

7. Install the cylinder block thermostats. Refer to "Cylinder BlockThermostatsInstallation" in Part 11-3for the proper procedure.

8. Install the waterpump. Referto "Water Pump Installation" inPart 11-2 for theproperprocedure.

9. Install the coolant supply tankandthermostat.Refer to "RadiatorSupply Tank and Thermostat Installation" in Part 11-3 for theproper procedure.

POWER FLUSHINGPROCEDURE

Modern cooling system powerflushing equipmentusesrust removing solvents. Most equipment hassight glasses to observeand determine whenthe systemis clean.Powerflushing is more efficient than thereverseflushing method.

If a power flushing machine isused, a "T" adapter part of theflushing equipment must be attachedto thecylinder blockasshownin Fig. 3.

Performthe power flushing procedure asfollows:

1. Perform Steps 1 through 4 ofthe "ReverseFlushingProcedure".

2. Install a "T" connectionon thecylinder block as shownin Fig. 3.

3. Flushthe engineuntil the wateror solvent runs clean.

4. Remove the flushing machineconnections. Perform Steps 6through 9 of the "ReverseFlushingProcedure". -

RADIATOR FLUSHINGPROCEDURE

1. Attach the pressure gun to theupper radiator hoseconnection.

2. Attach an outlet hose to theradiator lower hose connection.

3. Flush the radiator until thewater or solvent runs clean. Do notuse pressures in excessof 12 psiwhen flushing the radiator.

WATER PUMP

1. Cleanthe gasketmounting surfacesof the waterpumpandcylinderblock.

2. Clean and inspect the seal seating surfaceof the water pump.

3. Clean the pump housing andinspect it for cracks, sand holes, improper machining, and damagedsurfaces.If the water pump housingis damaged beyond repair, replacethe completewater pump.

242

"T" Adapter to FlushingUsed with Power Flushing Equipment 921-A

243

a unit Fig. 6. Discard the shaftandbearingassembly.CLEANING AND INSPECTION

Refer to Part 11-1, Section 4 forthe cleaning and inspection procedures.

- 11-5

PARTWATER PUMP112

Section Page Section PageI Description and Operation 11-5 3 Major Repair Operations 11-52 Removal and Installation 11-5

O DESCRIPTION AND OPERATIONThe water pump is a centrifugal- anddraws coolantfrom the radiator from the pump impeller, equally to

type with a castiron impeller. The when the thermostat in the intake both cylinder banks.impeller shaft is supported by a manifold is open. A bypassport on The waterpump pulley is presseddouble-row,sealedball bearingthat the water pump is connectedto the a specified distanceonto the wateris permanently lubricated. It re- intake manifold to draw coolant pump shaft.The pulley is driven byquires no additional lubrication.

The water pump is mounted on fromit whenthethermostatis closed, the crankshaftdamperthrough twothe front of the cylinder block. The bypassingthe radiator. V-belts. The water pump pulleyinlet port of the water pump is con- The water pump has two outlet mounts the cooling fan and spacernectedto the radiator left side tank ports to distribute the coolant flow, or fan drive clutch.

O REMOVAL AND INSTALLATIONREMOVAL 7. Removethewaterpump retain- thepulley sheaves.Closethe radiator

ing bolts. Position the oil dipstick draincock.1. Removethe ground cablefrom tube bracket and power steering 6. Adjust the alternator to obtainthe battery.Drain the cooling system. pump bracketto allow clearancefor the specified belt tension. Tighten2. On a car with an air condi- removalof thewaterpump. Remove the alternatoradjusting bracketbolt.

tioner, remove the power booster the water pump and mounting Tighten the alternator mountingfan clutch, fan bladeandcompressor gaskets. bolts. Install the alternator splashdrive pulley. Refer to "Fan Drive shield.Clutch Removal"in Part 11-4 for the INSTALLATION 7. On a car with an air condiproperprocedure.Removetheradi- 1. Coat two new water pump tioner, install the compressordriveator supplytank. Referto "Radiator gaskets with water-resistantsealer. pulley, fan drive clutch and fan as-Supply Tank and Thermostat Re- Install the gaskets on the water sembly and compressor*drive belt.moval" in Part 11-3 for the proper Install the radiator supply tank, ignipump.procedure. 2. Insert the water pump bypass tion coil, overflow hose and the

3. If the vehicleis equippedwith tubeinto the bypasshose.Make cer- radiator inlet hose.Refer to "Radiastandardcoolingcomponents,remove tam the retaining clamp is on the tor Supply Tank and Thermostatthe, fan and spacer. Refer to "Fan hose.Position the water pump and Installation" in Part 11-3 for theReinoval"in Part 11-1 for the proper gasketson the cylinder block, proper installation procedure. Fillremoval procedure. 3. Position the oil dipstick tube the cooling system to the required

4. Loosen the clamp securing the bracket, power steering reservoir level. Start the engineand checkforbypasshose to the water pump. bracket, and alternator adjusting coolantleakage.Referto "Fan Drive

5. Remove the alternator splash bracket on the water pump. Install Clutch Installation" in Part 11-4 forshield. Loosenthe alternatoradjust- the water pump mountingbolts and the proper installation procedure.ing bracket and mounting bracket torquethem to specifications. 8. If the vehicle is equippedwithbolts. Push the alternator inward 4. Connectthe heateroutlet hose standardcooling components,installand removethe drive belts. to the water pump fitting. Tighten the fan and spacer. Fill the cooling

6. Disconnect the radiator outlet the bypass hose clamp, systemto therequiredlevel. Start thehose at the water pump. Disconnect 5. Connectthe radiatoroutlethose engineandcheck for leakage.Referthe heaterhose at the water pump to the water pump. Install thewater to "Fan Installation" in Part 11-1 forfitting. pump and alternator drive belts on the proper installation procedure.

MAJOR REPAIR OPERATIONSDISASSEMBLY pulley with the useof steeringwheel

The waterpumpassemblyis shown remover tool 3600-AA as shown inin Fig. 4. Fig. 5.

1. Remove the impeller cover 3. Install the water pump on anarbor press and press out the impeller, sealand shaft andbearingas

plate and gasket.2. Removethe water pump drive

244GROUP 11-COOLING SYSTEM

FIG. 5-Water Pump PulleyRemovalASSEMBLY

When assemblingthe waterpump,always usenew gaskets,seal, shaftand bearingassembly,and impeller.

1. Support the water pump on anarbor press Fig. 7. Position theshaft and bearing assembly in thewater pump with the slinger facingdownward. Pressthe shaft, bearing

Arbor Press

SHAFT AND L00" Bar StockBEARING ASSEMBLY

FIG. 6-Shaft and Bearing, Sealand Impeller Removal

FIG. i-Installing Water PumpShaft and Bearingand slinger assemblyinto the waterpump housing until the bearing isflush with the hub edgeof the housing.

2. Support the water pump housing on its hub edge and insert thesealassemblyoverthe shaft with thebrass flange of the seal facing upward. Place the recessedend of the

Arbor Press’,

Tool-8507-DD-18

SEAL:

I. ..

81923-A

FIG. 9-Water Pump ImpellerInstallationtool 8501-DD-18 over the seal andpress the seal inward until it -seatsFig. 8.

3. Position the water pump assembly on an arbor press with thepulley mountingendof theshaft andbearing assemblyrestingon a steelplate. Carefully press the impelleronto the shaft until the rear face ofthe impeller sets 0.105 to 0.115 inchbelow the cover mounting face ofthe water pump. Check the dimension, using a straight edge and afeeler gauge Fig. 9.

4. Position the water pump on anarbor press with a steel block supporting the shaftandbearingassembly at the impeller mounting end.Position the water pump pulley onthe shaft and press the pulley ontothe shaft until a dimension of 7%2

inch is obtained betweenthe frontface of the pulley and the mountingface of the water pump "legs" Fig.10.

5. Coat the water pump covergasket with a water-resistant;non-hardeningsealing compound. Installthe gasket and cover. Tighten themounting bolts.

11-6

SLINGER

GASKET

SHAFT AND

COVER PLATE

.105" Feeler Gouge ....85O1-D0-18J /Strthght Edge

GASKET

FIG. 4-Water Pump and Pulley

Lj

-

- 81924-A

- Arbor Press

Tool-- 7657-FSHAFT

BEARING

81927-A

Arbor Press

I iL. .L.. -

T ThTh -- -- -

FIG. 8-Water Pump SealInstallation

- -

81925-A

FIG. lO-Water Pump PuHeyInstallation

-245 11-7

PART RADIATOR, SUPPLY TANK AND

11-3 THERMOSTATS -

Section Page Section Page1 Description and Operation 11-7 2 Removal and Installation 11-8

0 DESCRIPTION AND OPERATIONRADIATOR

A cellular-tubular, crossflow radiator Fig. 11 is used in all carmodels. An extra-coolingradiator isavailable as optional equipmenttosatisfy climatic and extra coolingrequirements.Extra-coolingradiatorsare standardequipmenton air conditioner-equippedcars.

Two headertanks, one on eachside of the radiator Fig. 11, provide uniform distributionof the coolant to the crossflow tubes. A heatexchanger located within the- leftside headertank of the radiatorprovidesmeansof cooling the transmission fluid. Inlet andoutlet fittings areprovided at the rear of the radiatorleft side headertank Fig. 11.

The radiatordrain cock is locatedat the lower rearof theradiatorrightside header tank. Cylinder blockdrain plugs are locatedon each bankof the cylinder block.

SUPPLY TANK

A radiator supply tank Fig. 11is provided on all models to controlsurging of the coolant. The supplytank is mountedto the intakemanifold coolant outlet port which contains the main thermostat.The supply tankmountingbracket is securedto the water pump. A radiatorrubber inlet hose connectsthe supplytank and the right side headertankof the radiator.

An overflow hose is connectedtothe supplytank andis securedto thecylinder front cover by meansof aclip. The ignition coil is securedtothe undersideof the supply tank bya clamp and bracket.

THERMOSTATS

A standard, high-temperature thermostat is locatedin the intake manifold coolant outlet. When non-permanent-type anti-freeze is to beused in the cooiing system, thehigh-temperature thermostat mustbe removed and replaced by a low-temperature thermostat to eliminate the possibility of the coolingsystem boiling off the anti-freeze.Also, two thermostatsarelocated inthe front faceof the cylinder block,one in eachcylinder bank Fig. 12.

TRANSMISSION COOLER LINES

TOR

SUPPLY TANK

POWER BOOSTER FAN CLUTCHWITH AIR CONDITIONING

Bi 933-A

FIG. li-Radiator and Supply Tank FIG. 12-Thermostat Locations

11-8 GROUP 11-COOLING SYSTEM

fl REMOVAL AND INSTALLATION

RADIATOR

REMOVAL

1, Raisethe front of the car. Openthe radiatordrain cock anddrainthecooling system.

2. Disconnect and remove theradiator inlet hose. Disconnect thetransmission fluid inlet and outletlines at the radiator. Plug the linesto prevent drainage and the entrance of foreign material.

3. Disconnect the radiator outlethose at the water pump.

4. Removethe threeradiatorlowermountingbolts.

5. On a car with an air conditioner, removethe two condensertoradiatorlower mounting bolts.

6. Remove the radiator supportshield. Disconnect the fuel linebracket from the radiator. Removethe radiator from the car. Use careto prevent radiator damage.

INSTALLATION

1. Close the radiator drain cockandposition the radiator in the car.

2. On a car with an air conditioner, install the condenser andradiator support shield on the radiator and insert the three mountingbolts. Do not tighten the bolts. Install the two condenserlower mounting bolts. Tighten the condenserupper andlower mountingbolts.

3. Install the radiator supportshield on the radiatorand loosely install the threemountingbolts.

4. Position the radiator insulatorsbetweenthe radiatorsupport brackets and the car underbody. Makecertain they are aligned with themounting bolt holes. Install theradiator lower bolts. Tighten theradiator lower and upper mountingbolts. Secure the radiator supportshield to the car body uppersupportpanel and tighten the five mountingbolts.

5. Install the radiator outlet hose,transmission fluid inlet and outlet

lines and the radiator inlet hose.Tighten the hose clamps.

6. Install the fuel line bracket onthe radiator.

7. Lower the car. Fill the coolingsystem to its required level. Startthe engineandcheckfor leakage.

RADIATOR SUPPLY TANKAND THERMOSTAT

REMOVAL

1. Disconnect the battery groundcable at the battery.

2. Remove the pressure cap fromthe radiatorsupply tank. Drain thecooling system to below the supplytank level.

3. Disconnect the overflow hosefrom the radiator supply tank. Remove thewater pump mounting boltsecuringthe supply tank brace, enginegroundstrapandbatterygroundcableto the waterpump.

4. Disconnect the radiator inlethose from the radiator and supplytank.

5. Disconnect the primary andsecondary wires from the ignitioncoil.

6. Remove the retaining boltssecuring the radiatorsupply tank tothe intake manifold. Remove thetank, gasketandthermostat.Removethe ignition coil from the supplytank.

INSTALLATION

1. Install the thermostat in theintake manifold with the copperpellet or element towards the engine. It is important that the thermostat be positioned correctly inthe intake manifold, If it is improperly positioned, it will causea retarded flow of coolant.

2. Coat the radiator supply tankgasketwith water-resistantsealerandinstall it on the intake manifold.

3. Install the ignition coil in thesupply tank mounting bracket andtighten the clamp.

4. Position the supply tankon theintake manifold and loosely installthe mountingbolts. Position the supply tank brace,engineground strapsand battery ground cable on thewater pump. Install the mountingbolt and torque it to specifications.Torque the supply tank mountingbolts to specifications.

5. Connect the overflow hose tothe supply tank. Connect the radiatorinlet hoseto the supplytank andradiator. Tighten the hose clamps.

6. Connect the primary and secondary wires to the ignition coil.Close the radiator drain cock. Connect the batteryground cable to thebattery.

7. Fill the supply tank to its required level with coolant and installthe pressurecap. Start the engineand checkfor coolantleakage.

CYLINDER BLOCKTHERMOSTATS

REMOVAL

1. Remove the water pump, following the proceduresin Part 11-2,"Water Pump Removal".

2. Pry the thermostats from thecylinder block with a screwdriverorthin bladechisel. It is impossibletocheckused thermostats due to thedamage that occurs to the unitsduring their removal. Do not attempt to repair them. Install newthermostats.

INSTALLATION

1. Clean the thermostat bores toremoverust and foreign material.

2. Install the thermostatswith thetemperaturebulb located inside ofthe cylinder block.

3. Carefully tap the thermostatsinto position in the cylinder block.Avoid damaging the thermostatsduring this operation.

4. Install the waterpump, following the procedures in Part 11-2,"Water Pump Installation".

246

247 11-9

PART11 A FAN DRIVE CLUTCHIl-LI

Section Page Section Page1 DescriptionandOperation 11-9 2 Removal andInstallation 11-9

0 DESCRIPTION AND OPERATIONAir-conditioner-equippedvehicles change.The unit also increasesus-

contain a fan drive clutch assembly, able enginehorsepowerduring higha six-bladedfan, a compressordrive speedoperation. -pulley, and a compressor clutch The fan drive clutch is controlled

located within the chamber causesufficient friction buildup to rotatethe housing and mountedfan. Con-versely, a decrease in underhood

drive belt, by a heat-sensitive,bi-metal springThe six-bladed fan is mountedat locatedon the clutch front cover. As

the rearof thefan drive clutch. The underhood temperatures increase,

temperaturesallows the heat-sensitive spring to close the valve andpermits the returnof the oil to the

clutch assembly and compressor this spring expands,causinga platedrive pulley are securedto the water within the unit to uncoveran open-pump drive pulley with four cap- ing between the oil reservoir and

reservoirsection of the unit. As thedrive chamber empties, the driveplate rotatesfreely and the fan no

screws. drive chambers. Centrifugal force longer receives torque from the en-The fan drive clutch and fan as- of the drive chamber, as it revolves gine. The unit permits slippage so

sembly is regulated by underhood at water pump pulley speed,causes that some fan rotation will be extemperaturesto control the fan rpm the fluid to enterthe drive chamber. perienced, even under low temas engine cooling requirements Landsandgrooves in the drive plate perature operation.

U REMOVAL AND INSTALLATIONThe fan drive clutch assemblyis

servicedonly as a unit. If malfunction occurs, the unit must be replaced.

REMOVAL1. Disconnectthe groundcable at

tle battery.2. Loosen the compressorsupport

bracket bolts and adjusting bracketbolts. Move the compressorinwardtowardthe engine.Removethecompressordrive belt.

3. Removethe four bolts securingthe fan drive clutch andcompressor

drive pulley to the water pumppulley. Removethefan drive clutch, fanandpulley as a unit.

4. Removethe four capscrewsanddisassemblethe fan from the fandrive clutch.

CLEANING AND INSPECTIONRefer to Part 11-1, Section4 for

the cleaning and inspection procedures.

INSTALLATION

2. Install the clutch assemblyandcompressordrive pulley on thewaterpump pulley and tighteh themounting bolts.

3. Install the compressor drivebelt on the compressorclutch andthe drive pulley. Adjust thecompressor to obtain the specified belt tension and tighten the compressortomounting bracket attaching bolts.Tightenthe supportbracket bolts.

4. Connect the ground cable tothe battery. Removethe fendercovers and closethe hood.

1. Install the fan on the fan driveclutchand tighten the capscrews.

11-10248

PART11-5

SPECIFICATIONS

COOLING FAN

WATER PUMP

DRIVE BELT TENSION

*Belt operatedfor a minimum of 10 minutes is considereda usedbelt.

COOLING SYSTEM CAPACITY

Cooling System

THERMOSTATS

TORQUE VALUES

NOTE: All specifications are given in ft-lbs unlessotherwise noted.

Water Pump to Cylinder Block 23-28Water Outlet I-lousing 12-15Fan and Pulley to Pulley Hub 10-15RadiatorLower Attachment 10-15RadiatorSupply Tank to Engine 20-28Radiator Supportto Air Deflector 10-15TransmissionOil Cooler Hose Tubeto Radiator 18-25TransmissionOil Cooler Hose Fittingto Radiator 10-12RadiatorHose Clampsto Radiator - -,

and Engine 1.0-2.5TransmissionOil Cooler TubesHoseClamps 15-20in-lbs

OUTSIDE No. OFDIAMETER BLADES

Standard 17.50 inches 4Air Conditioner-Equipped.... 18.25 inches 5

MAIN THERMOSTATS

Low Temperature

Opens °F 155°-162°Fully Open °F 182°

High Temperature

Opens °F 185°-192°Fully Open °F 212°

CYLINDER BLOCK THERMOSTATS

Opens °F 137°-142°Fully Open °F 162°

WATER PUMP DRIVE ARRANGEMENT

Dual belts drive waterpump, fan andalternator

WATER PUMP PULLEY TO ENGINE RATIO

Extra Cooling With Air Conditioning ... .1.25:1StandardCooling 1.25:1

WATER PUMP ASSEMBLY DIMENSIONS

Front Faceof Pulley Hub toPump HousingFace 7.094inchesImpeller to Housing Clearance..0.105-0.115inches

BETWEEN ALTERNATOR AND WATER PUMP PULLEY

New-Front 110-135Rear 105-140

*UsedFront 90-110Rear 85-115

BETWEEN WATER PUMP AND AIR COMPRESSOR PULLEY

New 120-150*Used 90-120

Approximate CapacityQuarts

U.S.

Standard 21