Thermostat - 4.2L: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the gasket mating surfaces with a plastic scraper and metal surface cleaner. Follow the directions on the packaging.

NOTE: The thermostat is indexed and must be installed as shown.

Install the thermostat in the water outlet connection and rotate the thermostat either clockwise or counterclockwise to engage the cam on the thermostat securely. The thermostat vent must be located either at the 11 o'clock or 1 o'clock position.
1. Thermostat vent shown at 11 o'clock.
2. Thermostat vent shown at 1 o'clock.
  
  Fig 1: Identifying Thermostat Vent Located Either At 11 O'Clock Or 1 O'Clock Position
  Courtesy of FORD MOTOR CO.
3. Position a new gasket and the coolant outlet connection and install the bolts. Tighten the bolts in 2 stages.
  - Stage 1: Tighten to 8 Nm (71 lb-in).
  - Stage 2: Tighten an additional 60 degrees.
4. Connect the upper radiator hose and position the clamp.
5. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .