Removal and Installation

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

Raise and support the vehicle.
Remove the front splash shield. For additional information, refer to FRONT END BODY PANELS .
Drain the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
Lower the vehicle.
Remove the air cleaner assembly. For additional information, refer to REMOVAL & INSTALLATION .
Remove the battery and battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Disconnect the upper radiator hose, the thermostat housing hose and the heater water hose.

Fig 1: Identifying Thermostat Housing Hose And Heater Water Hose
Courtesy of FORD MOTOR CO.
Disconnect the engine coolant temperature (ECT) sensor and the water temperature sender electrical connector.

Fig 2: Identifying Engine Coolant Temperature (ECT) Sensor And Water Temperature Sender Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect and remove the radiator bypass hose assembly.

Fig 3: Disconnecting Radiator Bypass Hose Assembly
Courtesy of FORD MOTOR CO.
Remove the bolt, the stud and the water pump bypass tube.
- Remove and discard the O-ring and gasket.
Fig 4: Identifying O-Ring And Gasket
Courtesy of FORD MOTOR CO.
To install, reverse the removal procedure.
Clean the sealing surfaces and install a new gasket and O-ring.