Radiator fins obstructed. Thermostat stuck open, or of in- tive causing gauge to indicate low

Transcription

1 PART 11-1 PAGE PART 11-4 PAGE GENERAL COOLING SYSTEM SERVICE FAN DRIVE CLUTCH 11-9 PART 11-2 WATER PUMP 11-5 PART 11-3 RADIATOR, SUPPLY TANK AND THERMOSTATS 11-7 PART 11-1 PART 11-5 SPECIFICATIONS GENERAL COOLING SYSTEM SERVICE Section Page Section Page 1 Diagnosis and Testing Common Adjustments and Repairs Maintenance Cleaning and Inspection 11-4 fl DIAGNOSIS AND TESTING DIAGNOSIS Coolant loss may also be caused by the oil level dipstick could be an ininternal leakage due to a defective dication of internal leakage. Engine overheating and slow encylinder head gasket, improper tight- Rust and scale that form in the gine warm-up are the two engine ening of the cylinder head bolts, or engine coolant passages are carried troubles most commonly attributed a warped cylinder head or cylinder into the radiator passages by the cir to the cooling system. block gasket surface. culation of the coolant. This clogs Loss of coolant, thermostat stuck Internal leakage can be detected the radiator passages and causes overin the closed position, or the accu- by operating the engine at fast idle heating. Rust can be detected by the mulation of rust and scale in the sys- and looking for the formation of appearance of the coolant. If the tern are the main causes of overheat- bubbles in the radiator supply tank. coolant has a rusty or muddy appear ing. Coolant loss may be caused by Oil in the radiator supply tank may ance, rust is present. external leakage at the radiator, ra- indicate leakage in the engine block A defective thermostat that re diator supply tank, water pump, hose or a leak in the automatic transmis- mains open will cause slow engine connections, heater and core plugs. sion oil cooler. Water formation on warm-up. DIAGNOSIS GUIDE ENGINE OVERHEATS ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE LOSS OF COOLANT Insufficient coolant. Cooling system passages blocked Belt tension incorrect, by rust, scale, or other foreign matter. Radiator fins obstructed. Water pump inoperative. Thermostat stuck closed. Faulty fan drive clutch. Thermostat stuck open, or of in- tive causing gauge to indicate low correct heat range. engine temperature. Temperature sending unit defec- Temperature gauge defective not indicating true engine temperature. Leaking radiator or radiator sup- head bolts. ply tank. Cylinder block core plugs leaking. loose or damaged hose connec- Cracked cylinder head or block, tions. or warped cylinder head or block Water pump leaking. gasket surface. Cylinder head gasket defective. Radiator pressure cap defective or Improper tightening of cylinder wrong type.

2 11-2 GROUP 11-COOLING SYSTEM 240 TESTING COOLING SYSTEM PRESSURE TEST It is recommended that a cooling system pressure test gauge be used to properly test the system for: 1. Blown or leaking cooling system sealing gaskets. 2. Internal or external coolant leakage. 3. Pressure cap malfunction. Many types of pressure gauges are available for use. Therefore, it is recommended that the gauge manu facturer s instructions be followed when performing the test. Never exceed the rated pressure indi cated on the pressure cap when performing the pressure test. THERMOSTAT TESTS Main Thermostat. Remove the thermostat and immerse it in boiling water. Replace the thermostat if it does not open more than 1/4 inch. If the problem being investigated is insufficient heat, the thermostat should be checked for leakage. This may be done by holding the thermo stat up to a lighted background. Light leakage around the thermostat valve thermostat at room tempera ture is unacceptable and the thermo stat should be replaced. It is possible, on some thermostats, that a slight leakage of light at one or two loca BI-METAL SPRING.7 FIG. i-power Booster Fan Drive Clutch tions on the perimeter of the valve may be detected. This should be con sidered normal. Cylinder Block Thermostats. It is impossible to check the operation of used cylinder block thermostats due to the distortion that occurs to the units during their removal from the cylinder block. Do not attempt to repair them. Install new thermo stats. If new thermostats are tested, fol low the procedure for the main thermostat test. FAN DRIVE CLUTCH TEST The recommended testing proce dure for the fan drive clutch Fig. 1 is as follows: 1. The viscosity of the silicone oil within the drive chamber of the unit directly affects its drive characteris tics. Therefore, the unit should not be cold when tested. When ambient air temperatures are below 65 F, operate the engine at approximately 1000 rpm for 20 minutes. This should produce the desired temperatures within the unit. However, regardless of the ambient air temperature, the unit must be operated for at least 5 minutes prior to testing. 2. Run the engine at approximately 1000 rpm until normal operating temperature is reached. This process can be speeded up by blocking off the front of the radiator with card board. 3. Stop the engine and, using a cloth to protect the hand, immedi ately check the effort required to turn the cooling fan. If considerable effort is required, it can be assumed that the coupling is operating satis factorily. If very little effort is re quired to turn the fan, it is an indication that the coupling is not operating properly and it should be replaced. o MAINTENANCE COOLANT Correct coolant level is essential for maximum circulation and ade quate cooling. In addition, for the cooling system to perform its func tion, it must receive proper care. This includes keeping the radiator fins clean and a periodic inspection of the cooling system for leakage. Use care when removing the radiator cap to avoid injury from escaping steam or hot water. In production, the cooling system is filled with a new long-life coolant. This coolant protects to -35 F. It will not be necessary to provide special anti-freeze protection except in areas where temperatures fall below this level. For year round pro tection from corrosion and over heating, and for low-temperature protection to -35 F, all coolant added should be a mixture of 50% Ford Rotunda coolant concentrate and water. Use of greater than a concentrate should be avoided to prevent possible over heating during warm weather. Do not mix permanent-type anti freeze with the methanol type. In areas where protection to -35 F is not required, but some protec tion is necessary, refer to the coolant mixture chart on the Ford Rotunda coolant can for the recommended mixture proportions. A standard ethylene glycoihydrom eter can be used to check the pro tection level of the long-life coolant. Refer to Group 19 for the recom mended cooling system drain in terval. DRAINING AND FILLING THE COOLING SYSTEM 1. Remove the radiator cap. Open the radiator drain cock and remove the cylinder block drain plugs to drain the cooling system. 2. Clean or flush the cooling sys tem, if required. 3. To fill the cooling system: Close the radiator drain cock and install the cylinder block drainplugs. Move the heater control dial in dicator clockwise to the "MAX" heat zone. Fill the system with coolant to a point one inch below the bottom of the supply tank filler neck. Install the pressure cap and turn it clockwise until the first stop is reached. This will allow the cooling system to vent entrapped air into the atmosphere. Do not tighten the cap fully. Operate the engine until normal operating temperatures are reached. After the initial fill, the coolant level drops due to the displace ment of entrapped air. Add more coolant to fill the supply tank to the required level. Tighten the pressure cap.

3 241 PART 11-1-GENERAL COOLING SYSTEM SERVICE Check the cooling system for leakage. Move the heater control dial indicator to the "MIN" heat zone. Turn the ignition key to the "OFF" position. FAN DRIVE BELTS If the fan drive belts are noisy, check the tension of the belts to make certain they are within speci fications. Also, check for misaligned pulleys. If the drive belts are worn or frayed, replace them following the procedures in Part 11-1, Section 3. 0 COMMON ADJUSTMENTS AND REPAIRS ADJUSTMENTS DRIVE BELTS The belts must be properly ad justed at all times. Loose belts cause improper fan, water pump and alter nator operation. A belt that is too tight places a severe strain on the water pump and the alternator bearings. Properly tensioned drive belts minimize noise and also prolong the service life of the belt. Therefore, it is recommended that a belt tension gauge be used to check and adjust the belt tension Fig. 2. Any belt that has operated for a minimum of 10 minutes is considered a used belt, and when adjusted, it must be adjusted to the reset tension shown in the specifications. Belt Tension 1. Remove the alternator splash shield. Loosen the alternator mount ing bolts. 2. Loosen the alternator adjusting bracket bolt. 3. Install the belt tension gauge on the fan drive belts. Move the alternator toward or away from the engine until the specified belt tension is obtai ied. Remove the gauge. Tighten the alternator adjusting bracket bolt; then tighten the alter nator mounting bolts. Install the tension gauge and check the belt tension. 4. On a car with an air condi tioner, remove the bolts securing the compressor to the support bracket that is attached to the cylin der head. Loosen the bolts securing the compressor to the compressor mounting bracket. Install the tension gauge on the compressor clutch drive belt. Move the compressor toward or away from the engine until the specified belt tension is obtained. Remove the gauge. Tighten the compressor to support bracket bolts. Install the tension gauge and check the belt tension. Too!- T A or ! FIG. 2-Fan Adjustment L 5. New belts: Operate the engine for ten minutes, then check the tension of the belts to make certain that they are within the reset speci fications. Adjust the belts, if required. 6. Install the alternator splash shield. REPAIRS FAN REPLACEMENT Removal 1. Remove the ground cable from the battery. 2. Loosen the bolts securing the fan blades and spacer to the water pump pulley. Remove the fan, spacer, and mounting bolts as a unit. On a car with an air conditioner, loosen the bolts securing the fan drive clutch to the water pum]p pulley. Remove the fan, drive clutch and mounting bolts as a unit. Installation Drive Belt Tension 1. Position the spacer or drive clutch and fan on the water pump pulley and install the mounting bolts. Tighten the bolts. 2. Connect the ground cable to the battery. FAN BELT REPLACEMENT 1. On a car with an air conditioner, loosen the air compressor to bracket mounting bolts. Move the air com pressor toward the engine and re move the compressor drive belt. 2. Remove the alternator splash shield. Loosen the alternator mount ing bolts and adjusting bracket bolts. 3. Move the alternator toward the engine, and remoye the fan drive belts. 4. Install the fan drive belts on the water pump pulley, crankshaft damper and alternator pulley. Ad just the belt tension to specifications, and tighten the alternator mounting bolts and adjusting bracket bolts. 5. On a car with an air conditioner, install the air compressor drive belt on the water pump pulley and the air compressor clutch. Adjust the drive belt tension to specifications, and tighten the air compressor to bracket mounting bolts. 6. Install the alternator splash shield. RADIATOR HOSE REPLACEMENT The radiator hoses should be replaced whenever they become cracked, rotted, or have a tendency to collapse. 1. Drain the radiator. Loosen the clamps on each end of the hose to be removed. Slide the clamps in toward the center of the hose. 2. Slide the hoses off the radiator connections. Remove the upper hose from the supply tank. Remove the lower hose from the water pump. 3. Position the hose clamps on the center of the radiator hoses. In stall the hoses on the respective connections and tighten the clamps firmly. Make sure the clamps are located beyond the bead on the connections. 4. Fill the radiator to the required level with coolant. Start the engine and check for coolant leaks. Check for proper coolant level after the engine has reached normal operating temperature. Add coolant as re quired.

4 11-4 GROUP 11-COOLING SYSTEM 0 CLEANING AND INSPECTION COOLING SYSTEM FLUSHING PROCEDURES The design of the cooling system requires that specific steps be taken to reverse flush the engine. Engine cooling system thermostats open in the direction of coolant flow. Due to this factor, it will be necessary to remove all thermostats to prevent back-pressure. The water pump must be removed to reach the cylinder block thermo stat. Due to this condition, it is more practical to reverse flush the engine separately from the radiator. REVERSE FLUSHING PROCEDURE 1. Remove the water pump. Refer to "Water Pump Removal" in Part 11-2 for the proper procedure. 2. Remove the cylinder block thermostats. Refer to "Cylinder Block Thermostats Removal" in Part 11-3 for the proper procedure. 3. Remove the coolant supply tank and thermostat. Refer to "Radiator Supply Tank and Thermostat Re moval" in Part 11-3 for the proper procedure. 4. Plug the coolant bypass tube. Connect a water pressure gun attach ment to the intake manifold as illus trated in Fig Flush the cylinder block until the system is clean. Remove the pres sure gun attachment. 6. Clean the gasket surfaces of the water pump, cylinder block, coolant supply tank and the intake manifold. WATER BY-PASS PLUG WATER / - - DISCHARGE I OPENINGS / Pressure Gun -- * Attachmer.t /._ FIG. 3-Reverse Flushing Procedures WATER,CHARGE OPENINGS "T" Adapter to Flushing Used with Power Flushing Equipment 7. Install the cylinder block ther mostats. Refer to "Cylinder Block Thermostats Installation" in Part 11-3 for the proper procedure. 8. Install the water pump. Refer to "Water Pump Installation" in Part 11-2 for the proper procedure. 9. Install the coolant supply tank and thermostat. Refer to "Radiator Supply Tank and Thermostat In stallation" in Part 11-3 for the proper procedure. POWER FLUSHING PROCEDURE 921-A Modern cooling system power flushing equipment uses rust remov ing solvents. Most equipment has sight glasses to observe and deter mine when the system is clean. Power flushing is more efficient than the reverse flushing method. If a power flushing machine is used, a "T" adapter part of the flushing equipment must be at tached to the cylinder block as shown in Fig. 3. Perform the power flushing proce dure as follows: 1. Perform Steps 1 through 4 of the "Reverse Flushing Procedure". 2. Install a "T" connection on the cylinder block as shown in Fig Flush the engine until the water or solvent runs clean. 4. Remove the flushing machine connections. Perform Steps 6 through 9 of the "Reverse Flushing Procedure". - RADIATOR FLUSHING PROCEDURE 1. Attach the pressure gun to the upper radiator hose connection. 2. Attach an outlet hose to the radiator lower hose connection. 3. Flush the radiator until the water or solvent runs clean. Do not use pressures in excess of 12 psi when flushing the radiator. WATER PUMP Clean the gasket mounting sur faces of the water pump and cylinder block. 2. Clean and inspect the seal seat ing surface of the water pump. 3. Clean the pump housing and inspect it for cracks, sand holes, im proper machining, and damaged surfaces. If the water pump housing is damaged beyond repair, replace the complete water pump.

5 PART 112 WATER PUMP Section Page Section Page I Description and Operation Major Repair Operations Removal and Installation 11-5 O DESCRIPTION AND OPERATION The water pump is a centrifugal- and draws coolant from the radiator from the pump impeller, equally to type with a cast iron impeller. The when the thermostat in the intake both cylinder banks. impeller shaft is supported by a manifold is open. A bypass port on The water pump pulley is pressed double-row, sealed ball bearing that the water pump is connected to the a specified distance onto the water is permanently lubricated. It reintake manifold to draw coolant pump shaft. The pulley is driven by quires no additional lubrication. The water pump is mounted on from it when the thermostat is closed, the crankshaft damper through two the front of the cylinder block. The bypassing the radiator. V-belts. The water pump pulley inlet port of the water pump is con- The water pump has two outlet mounts the cooling fan and spacer nected to the radiator left side tank ports to distribute the coolant flow, or fan drive clutch. O REMOVAL AND INSTALLATION REMOVAL 7. Remove the water pump retain- the pulley sheaves. Close the radiator ing bolts. Position the oil dipstick drain cock. 1. Remove the ground cable from tube bracket and power steering 6. Adjust the alternator to obtain the battery. Drain the cooling system. pump bracket to allow clearance for the specified belt tension. Tighten 2. On a car with an air condi- removal of the water pump. Remove the alternator adjusting bracket bolt. tioner, remove the power booster the water pump and mounting Tighten the alternator mounting fan clutch, fan blade and compressor gaskets. bolts. Install the alternator splash drive pulley. Refer to "Fan Drive shield. Clutch Removal" in Part 11-4 for the INSTALLATION 7. On a car with an air condi proper procedure. Remove the radi- 1. Coat two new water pump tioner, install the compressor drive ator supply tank. Refer to "Radiator gaskets with water-resistant sealer. 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 pump. Install the radiator supply tank, igni procedure. 2. Insert the water pump bypass tion coil, overflow hose and the 3. If the vehicle is equipped with tube into the bypass hose. Make cer- radiator inlet hose. Refer to "Radia standard cooling components, remove tam the retaining clamp is on the tor Supply Tank and Thermostat the, fan and spacer. Refer to "Fan hose. Position the water pump and Installation" in Part 11-3 for the Reinoval" in Part 11-1 for the proper gaskets on the cylinder block, proper installation procedure. Fill removal 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 engine and check for bypass hose to the water pump. bracket, and alternator adjusting coolant leakage. Refer to "Fan Drive 5. Remove the alternator splash bracket on the water pump. Install Clutch Installation" in Part 11-4 for shield. Loosen the alternator adjust- the water pump mounting bolts and the proper installation procedure. ing bracket and mounting bracket torque them to specifications. 8. If the vehicle is equipped with bolts. Push the alternator inward 4. Connect the heater outlet hose standard cooling components, install and remove the drive belts. to the water pump fitting. Tighten the fan and spacer. Fill the cooling 6. Disconnect the radiator outlet the bypass hose clamp, system to the required level. Start the hose at the water pump. Disconnect 5. Connect the radiator outlet hose engine and check for leakage. Refer the heater hose at the water pump to the water pump. Install the water to "Fan Installation" in Part 11-1 for fitting. pump and alternator drive belts on the proper installation procedure. MAJOR REPAIR OPERATIONS DISASSEMBLY pulley with the use of steering wheel The water pump assembly is shown remover tool 3600-AA as shown in in Fig. 4. Fig Remove the impeller cover 3. Install the water pump on an plate and gasket. 2. Remove the water pump drive arbor press and press out the im peller, seal and shaft and bearing as a unit Fig. 6. Discard the shaft and bearing assembly. CLEANING AND INSPECTION Refer to Part 11-1, Section 4 for the cleaning and inspection proce dures.

6 11-6 GROUP 11-COOLING SYSTEM 244 SLINGER.105" Feeler Gouge...85O1-D0-18 GASKET COVER PLATE J/Strthght Edge SHAFT AND FIG. 4-Water Pump and Pulley FIG. 5-Water Pump Pulley Removal ASSEMBLY When assembling the water pump, always use new gaskets, seal, shaft and bearing assembly, and impeller. 1. Support the water pump on an arbor press Fig. 7. Position the shaft and bearing assembly in the water pump with the slinger facing downward. Press the shaft, bearing Arbor Press SHAFT AND BEARING ASSEMBLY L00" Bar Stock GASKET A FIG. i-installing Water Pump Shaft and Bearing and slinger assembly into the water pump housing until the bearing is flush with the hub edge of the hous ing. 2. Support the water pump hous ing on its hub edge and insert the seal assembly over the shaft with the brass flange of the seal facing up ward. Place the recessed end of the : SHAFT BEARING Arbor Press, Tool DD-18 SEAL - Arbor Press Tool F Lj A FIG. 9-Water Pump Impeller Installation tool 8501-DD-18 over the seal and press the seal inward until it -seats Fig Position the water pump as sembly on an arbor press with the pulley mounting end of the shaft and bearing assembly resting on a steel plate. Carefully press the impeller onto the shaft until the rear face of the impeller sets to inch below the cover mounting face of the water pump. Check the dimen sion, using a straight edge and a feeler gauge Fig Position the water pump on an arbor press with a steel block sup porting the shaft and bearing assem bly at the impeller mounting end. Position the water pump pulley on the shaft and press the pulley onto the shaft until a dimension of 7%2 inch is obtained between the front face of the pulley and the mounting face of the water pump "legs" Fig Coat the water pump cover gasket with a water-resistant; nonhardening sealing compound. Install the gasket and cover. Tighten the mounting bolts. I L..L.. - T ThTh -- i -- - Arbor Press I... FIG. 6-Shaft and Bearing, Seal and Impeller Removal FIG. 8-Water Pump Seal Installation A - - FIG. lo-water Pump PuHey Installation A

7 PART RADIATOR, SUPPLY TANK AND THERMOSTATS Section Page Section Page 1 Description and Operation Removal and Installation RADIATOR DESCRIPTION AND OPERATION A cellular-tubular, crossflow radi ator Fig. 11 is used in all car models. An extra-cooling radiator is available as optional equipment to satisfy climatic and extra cooling requirements. Extra-cooling radiators are standard equipment on air con ditioner-equipped cars. TRANSMISSION COOLER LINES Two header tanks, one on each side of the radiator Fig. 11, pro vide uniform distribution of the cool ant to the crossflow tubes. A heat exchanger located within the- left side header tank of the radiator pro vides means of cooling the transmis sion fluid. Inlet and outlet fittings are provided at the rear of the radiator left side header tank Fig. 11. TOR SUPPLY TANK The radiator drain cock is located at the lower rear of the radiator right side header tank. Cylinder block drain plugs are located on each bank of the cylinder block. SUPPLY TANK A radiator supply tank Fig. 11 is provided on all models to control surging of the coolant. The supply tank is mounted to the intake mani fold coolant outlet port which con tains the main thermostat. The sup ply tank mounting bracket is secured to the water pump. A radiator rub ber inlet hose connects the supply tank and the right side header tank of the radiator. An overflow hose is connected to the supply tank and is secured to the cylinder front cover by means of a clip. The ignition coil is secured to the underside of the supply tank by a clamp and bracket. THERMOSTATS A standard, high-temperature ther mostat is located in the intake mani fold coolant outlet. When non-per manent-type anti-freeze is to be used in the cooiing system, the high-temperature thermostat must be removed and replaced by a lowtemperature thermostat to elimi nate the possibility of the cooling system boiling off the anti-freeze. Also, two thermostats are located in the front face of the cylinder block, one in each cylinder bank Fig. 12. POWER BOOSTER FAN CLUTCH WITH AIR CONDITIONING Bi 933-A FIG. li-radiator and Supply Tank FIG. 12-Thermostat Locations

8 11-8 GROUP 11-COOLING SYSTEM fl REMOVAL RADIATOR REMOVAL 1, Raise the front of the car. Open the radiator drain cock and drain the cooling system. 2. Disconnect and remove the radiator inlet hose. Disconnect the transmission fluid inlet and outlet lines at the radiator. Plug the lines to prevent drainage and the en trance of foreign material. 3. Disconnect the radiator outlet hose at the water pump. 4. Remove the three radiator lower mounting bolts. 5. On a car with an air condi tioner, remove the two condenser to radiator lower mounting bolts. 6. Remove the radiator support shield. Disconnect the fuel line bracket from the radiator. Remove the radiator from the car. Use care to prevent radiator damage. INSTALLATION 1. Close the radiator drain cock and position the radiator in the car. 2. On a car with an air condi tioner, install the condenser and radiator support shield on the radi ator and insert the three mounting bolts. Do not tighten the bolts. In stall the two condenser lower mount ing bolts. Tighten the condenser upper and lower mounting bolts. 3. Install the radiator support shield on the radiator and loosely in stall the three mounting bolts. 4. Position the radiator insulators between the radiator support brack ets and the car underbody. Make certain they are aligned with the mounting bolt holes. Install the radiator lower bolts. Tighten the radiator lower and upper mounting bolts. Secure the radiator support shield to the car body upper support panel and tighten the five mounting bolts. 5. Install the radiator outlet hose, transmission fluid inlet and outlet AND INSTALLATION lines and the radiator inlet hose. Tighten the hose clamps. 6. Install the fuel line bracket on the radiator. 7. Lower the car. Fill the cooling system to its required level. Start the engine and check for leakage. RADIATOR SUPPLY TANK AND THERMOSTAT REMOVAL 1. Disconnect the battery ground cable at the battery. 2. Remove the pressure cap from the radiator supply tank. Drain the cooling system to below the supply tank level. 3. Disconnect the overflow hose from the radiator supply tank. Re move the water pump mounting bolt securing the supply tank brace, en gine ground strap and battery ground cable to the water pump. 4. Disconnect the radiator inlet hose from the radiator and supply tank. 5. Disconnect the primary and secondary wires from the ignition coil. 6. Remove the retaining bolts securing the radiator supply tank to the intake manifold. Remove the tank, gasket and thermostat. Remove the ignition coil from the supply tank. INSTALLATION 1. Install the thermostat in the intake manifold with the copper pellet or element towards the en gine. It is important that the ther mostat be positioned correctly in the intake manifold, If it is im properly positioned, it will cause a retarded flow of coolant. 2. Coat the radiator supply tank gasket with water-resistant sealer and install it on the intake manifold. 3. Install the ignition coil in the supply tank mounting bracket and tighten the clamp. 4. Position the supply tank on the intake manifold and loosely install the mounting bolts. Position the sup ply tank brace, engine ground straps and battery ground cable on the water pump. Install the mounting bolt and torque it to specifications. Torque the supply tank mounting bolts to specifications. 5. Connect the overflow hose to the supply tank. Connect the radi ator inlet hose to the supply tank and radiator. Tighten the hose clamps. 6. Connect the primary and sec ondary wires to the ignition coil. Close the radiator drain cock. Con nect the battery ground cable to the battery. 7. Fill the supply tank to its re quired level with coolant and install the pressure cap. Start the engine and check for coolant leakage. CYLINDER BLOCK THERMOSTATS REMOVAL 1. Remove the water pump, fol lowing the procedures in Part 11-2, "Water Pump Removal". 2. Pry the thermostats from the cylinder block with a screwdriver or thin blade chisel. It is impossible to check used thermostats due to the damage that occurs to the units during their removal. Do not at tempt to repair them. Install new thermostats. INSTALLATION Clean the thermostat bores to remove rust and foreign material. 2. Install the thermostats with the temperature bulb located inside of the cylinder block. 3. Carefully tap the thermostats into position in the cylinder block. Avoid damaging the thermostats during this operation. 4. Install the water pump, follow ing the procedures in Part 11-2, "Water Pump Installation".

9 PART 11 A FAN DRIVE CLUTCH Il-LI Section Page Section Page 1 Description and Operation Removal and Installation DESCRIPTION AND OPERATION Air-conditioner-equipped vehicles change. The unit also increases uscontain a fan drive clutch assembly, able engine horsepower during high sufficient friction buildup to rotate located within the chamber cause a six-bladed fan, a compressor drive speed operation. - the housing and mounted fan. Conversely, a decrease in underhood pulley, and a compressor clutch The fan drive clutch is controlled drive belt, by a heat-sensitive, bi-metal spring temperatures allows the heat-sensi The six-bladed fan is mounted at located on the clutch front cover. As tive spring to close the valve and the rear of the fan drive clutch. The underhood temperatures increase, permits the return of the oil to the clutch assembly and compressor this spring expands, causing a plate reservoir section of the unit. As the drive pulley are secured to the water within the unit to uncover an openpump drive pulley with four cap- ing between the oil reservoir and plate rotates freely and the fan no drive chamber empties, the drive 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 ex temperatures to control the fan rpm the fluid to enter the drive chamber. perienced, even under low tem as engine cooling requirements Lands and grooves in the drive plate perature operation. U REMOVAL The fan drive clutch assembly is serviced only as a unit. If malfunc tion occurs, the unit must be re placed. REMOVAL 1. Disconnect the ground cable at tle battery. 2. Loosen the compressor support bracket bolts and adjusting bracket bolts. Move the compressor inward toward the engine. Remove the com pressor drive belt. 3. Remove the four bolts securing the fan drive clutch and compressor AND INSTALLATION drive pulley to the water pump pul ley. Remove the fan drive clutch, fan and pulley as a unit. 4. Remove the four capscrews and disassemble the fan from the fan drive clutch. CLEANING AND INSPECTION Refer to Part 11-1, Section 4 for the cleaning and inspection proce dures. INSTALLATION 1. Install the fan on the fan drive clutch and tighten the capscrews. 2. Install the clutch assembly and compressor drive pulley on the water pump pulley and tighteh the mount ing bolts. 3. Install the compressor drive belt on the compressor clutch and the drive pulley. Adjust the compres sor to obtain the specified belt ten sion and tighten the compressor to mounting bracket attaching bolts. Tighten the support bracket bolts. 4. Connect the ground cable to the battery. Remove the fender cov ers and close the hood.

10 PART 11-5 SPECIFICATIONS COOLING FAN THERMOSTATS WATER DRIVE BELT PUMP TENSION OUTSIDE DIAMETER No. OF BLADES Standard inches 4 Air Conditioner-Equipped inches 5 WATER PUMP DRIVE ARRANGEMENT Dual belts drive water pump, fan and alternator WATER PUMP PULLEY TO ENGINE RATIO Extra Cooling With Air Conditioning :1 Standard Cooling 1.25:1 WATER PUMP ASSEMBLY DIMENSIONS Front Face of Pulley Hub to Pump Housing Face inches Impeller to Housing Clearance inches BETWEEN ALTERNATOR AND WATER PUMP PULLEY New-Front Rear *UsedFront Rear BETWEEN WATER PUMP AND AIR COMPRESSOR PULLEY New *Used *Belt operated for a minimum of 10 minutes is con sidered a used belt. MAIN THERMOSTATS TORQUE Low Temperature Opens F Fully Open F 182 High Temperature Opens F Fully Open F 212 CYLINDER BLOCK THERMOSTATS Opens F Fully Open F 162 VALUES NOTE: All specifications are given in ft-lbs unless otherwise noted. - Water Pump to Cylinder Block Water Outlet I-lousing Fan and Pulley to Pulley Hub Radiator Lower Attachment Radiator Supply Tank to Engine Radiator Support to Air Deflector Transmission Oil Cooler Hose Tube to Radiator Transmission Oil Cooler Hose Fitting to Radiator Radiator Hose Clamps to Radiator -, and Engine Transmission Oil Cooler Tubes Hose Clamps in-lbs COOLING SYSTEM CAPACITY Cooling System Approximate Capacity Quarts U.S. Standard 21