Ford Mustang (1999-2004) Service Manual: Cooling System Draining, Filling and Bleeding

Material

Draining

WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine is cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, turn and remove the pressure relief cap (still with a cloth).

CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly.

NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant should be drained and filled with new coolant.

1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise or the radiator cap counterclockwise to the first stop. When the pressure is released, remove the pressure relief cap/radiator cap.

2. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the fluid cooler. Open the draincock and drain the engine coolant.

• Close the radiator draincock.

Filling - 3.8L

CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types.

CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency, and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.

When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.

To maintain the integrity of the coolant and the cooling system:

• Add Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Use the same coolant that was drained from the cooling system. Do not mix coolant types.
• Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.
• Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
• Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications.

  Use of such coolants can harm the engine and cooling system components.

NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

1. Place the heater temperature selector in the maximum cool position.

2. CAUTION: On 3.8L engines, the vent plug must be removed before radiator fill or the engine may not fill completely.

NOTE: It is important to maintain engine coolant concentrate between 40 percent or -24C (-11 F) and 60 percent or -52C (-62F).

Fill the engine cooling system with 50/50 mixture of water and engine coolant.

3. After filling the engine cooling system, add coolant to the vent until full. Install the vent plug.

4. Leave the pressure relief cap off and run the engine until it reaches normal operating temperature.

5. Stop the engine and add the correct engine coolant mixture to the degas bottle/coolant expansion tank until the coolant level is between the COOLANT FILL LEVEL marks.

6. Turn the engine off and allow the cooling system to cool. Check the level in the degas bottle/coolant expansion tank, and add a 50/50 mix as needed.

Filling - 4.6L (2V)

CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types.

CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency, and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.

When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.

To maintain the integrity of the coolant and the cooling system:

• Add Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Use the same coolant that was drained from the cooling system. Do not mix coolant types.
• Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.
• Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
• Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications.

  Use of such coolants can harm the engine and cooling system components.

NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

1. Remove the thermostat. For additional information, refer to Thermostat-4.6L(2V) in this section.

2. Disconnect the heater core coolant supply hose from the fitting at the rear of the manifold.

3. Add the coolant/water mixture through the thermostat opening until coolant appears at the heater core coolant supply outlet fitting at the rear of the manifold.

4. Install the heater hose, using an appropriately sized worm style clamp in place of the constant tension clamp.

5. Reinstall the thermostat gasket (O-ring) and the thermostat. For additional information, refer to Thermostat-4.6L(2V) in this section.

6. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the "COOLANT FILL LEVEL" marks and replace the pressure cap.

7. Select the maximum cool temperature setting.

8. Run the engine until it reaches operating temperature.

9. CAUTION: If the engine coolant temperature gauge does not move, the engine coolant level in the engine is low and must be filled. Stop the engine, allow it to cool and fill the cooling system.

Add the correct engine coolant mixture to the degas bottle until the coolant level is between the "COOLANT FILL LEVEL" marks.

10. Repeat the two previous steps until the engine coolant mixture is between the "COOLANT FILL LEVEL" marks on the degas bottle. Turn off the engine and allow it to cool.

11. Check the freeze protection of the engine coolant mixture with the Battery/Anti-freeze Tester 014-R1060 or equivalent. Adjust freezing point range if necessary.

Filling - Cobra

CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types.

CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency, and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.

When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.

To maintain the integrity of the coolant and the cooling system:

• Add Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Use the same coolant that was drained from the cooling system. Do not mix coolant types.
• Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.
• Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
• Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications.

  Use of such coolants can harm the engine and cooling system components.

NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

1. Check all hose clamps for correct tightness. Make sure the radiator draincock is closed.

2. Place the heater temperature selector in maximum cool position.

3. Remove the pressure cap from the cooling system reservoir and the fill plug from the engine crossover tube.

4. CAUTION: Do not fill the cooling system through the reservoir only. Coolant will not enter the engine. Only the reservoir and the radiator will be filled and engine overheating will occur.

Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill neck on the cooling system reservoir.

5. Install the cooling system pressure cap on the reservoir.

6. Continue to fill the cooling system at the engine crossover fill neck until full.

7. Install the engine crossover tube fill plug.

8. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan has been first examined for possible cracks and separation.

CAUTION: If the engine temperature gauge does not move, coolant level is low in the engine and must be filled. Stop the engine, allow to cool, and fill the cooling system as outlined.

Run the engine until the thermostat opens (coolant flowing through the radiator lower hose becomes hot).

9. Stop the engine and allow to cool.

10. Add coolant to the engine crossover tube fill neck until the cooling system is full.

11. Install the fill plug.

12. Repeat the fill procedure if necessary.

Filling - Mach I

CAUTION: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types.

CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency, and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle.

When adding engine coolant, use a 50/50 mixture of engine coolant and deionized water.

To maintain the integrity of the coolant and the cooling system:

• Add Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Use the same coolant that was drained from the cooling system. Do not mix coolant types.
• Do not add/mix orange-colored Motorcraft Speciality Orange Engine Coolant VC-2 or equivalent meeting Ford specification WSS-M97B44-D. Mixing coolants may degrade the coolant's corrosion protection.
• Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
• Do not mix with recycled coolant unless it meets the requirements of Ford specification WSS-M97B51-A1. Not all coolant recycling processes meet these Ford specifications.

  Use of such coolants can harm the engine and cooling system components. Do not mix coolant types

NOTE: The addition of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan.

1. Remove the air intake scoop. For additional information, refer to Section.

2. Check all hose clamps for correct tightness. Make sure the radiator draincock is closed.

3. Place the heater temperature selector in maximum cool position.

4. Remove the pressure cap from the cooling system reservoir and the fill plug from the engine crossover tube.

5. CAUTION: Do not fill the cooling system through the reservoir only. Coolant will not enter the engine. Only the reservoir and the radiator will be filled and engine overheating will occur.

Add coolant into the fill neck on the engine crossover tube until coolant reaches the top of the fill neck on the cooling system reservoir.

6. Install the cooling system pressure cap on the reservoir.

7. Continue to fill the cooling system at the engine crossover fill neck until full.

8. Install the engine crossover tube fill plug.

9. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine with the hood open until the fan has been first examined for possible cracks and separation.

CAUTION: If the engine temperature gauge does not move, coolant level is low in the engine and must be filled. Stop the engine, allow to cool, and fill the cooling system as outlined.

Run the engine until the thermostat opens (coolant flowing through the radiator lower hose becomes hot).

10. Stop the engine and allow to cool.

11. Add coolant to the engine crossover tube fill neck until the cooling system is full.

12. Install the fill plug.

13. Repeat the fill procedure if necessary.

14. Install the air intake scoop. For additional information, refer to Section.

Bleeding

1. Select the maximum heater temperature and blower motor speed settings. Position the control to discharge air at A/C vents in instrument panel.

2. Start the engine and allow to idle. While engine is idling, feel for hot air at A/C vents.

3. CAUTION: If the air discharge remains cool and the engine coolant temperature gauge does not move, the engine coolant level is low and must be filled. Stop the engine, allow the engine to cool and fill cooling system.

Start the engine and allow it 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 in the middle of the NORMAL range. The upper radiator hose should feel hot to the touch.

4. Shut the engine off and allow the engine to cool.

5. Check the engine for coolant leaks.

6. Check the engine coolant level in the degas bottle/coolant expansion tank and fill as necessary.