• HEADINGS
  • BLEEDING
    • COOLING SYSTEM
      • Aerostar, Explorer, Mountaineer, Ranger & Windstar
      • Bronco, Pickup & Van
      • Expedition
      • Villager
  • BELT ADJUSTMENT
  • DRIVE BELT ROUTING
    • Drive Belt Routing (2.3L)
    • Drive Belt Routing (3.0L Aerostar & Ranger)
    • Drive Belt Routing (3.0L Villager)
    • Drive Belt Routing (3.0L Windstar)
    • Drive Belt Routing (3.8L Windstar)
    • Drive Belt Routing (4.0L OHV Explorer)
    • Drive Belt Routing (4.0L SOHC Explorer)
    • Drive Belt Routing (4.0L Ranger)
    • Drive Belt Routing (4.2L Pickup & Van - 1997)
    • Drive Belt Routing (4.6L Expedition)
    • Drive Belt Routing (4.6L, 5.4L & 6.8L Pickup & Van - 1997)
    • Drive Belt Routing (4.9L Pickup & Van - 1996)
    • Drive Belt Routing (5.0L Explorer & Mountaineer)
    • Drive Belt Routing (5.0L - 1996 & 5.8L Pickup & Van)
    • Drive Belt Routing (5.4L Expedition)
    • Drive Belt Routing (7.3L Diesel)
    • Drive Belt Routing (7.5L)
  • SPECIFICATIONS
    • COOLING SYSTEM SPECIFICATIONS
• FIGURES
  • Fig. 1: Locating Air Relief Plug (Villager)
  • Fig. 2: Holding Negative Pressure Relief Valve Open
  • Fig. 3: Aligning Serpentine Belt
  • Fig. 4: Drive Belt Routing (2.3L Without A/C Or P/S)
  • Fig. 5: Drive Belt Routing (2.3L With P/S)
  • Fig. 6: Drive Belt Routing (2.3L With A/C & P/S)
  • Fig. 7: Drive Belt Routing (3.0L Aerostar & Ranger With P/S)
  • Fig. 8: Drive Belt Routing (3.0L Aerostar & Ranger With A/C & P/S)
  • Fig. 9: Drive Belt Routing (3.0L Villager)
  • Fig. 10: Drive Belt Routing (3.0L Windstar)
  • Fig. 11: Drive Belt Routing (3.8L Windstar)
  • Fig. 12: Drive Belt Routing (4.0L OHV Explorer)
  • Fig. 13: Drive Belt Routing (4.0L SOHC Explorer)
  • Fig. 14: Drive Belt Routing (4.0L Ranger With A/C & P/S)
  • Fig. 15: Drive Belt Routing (4.0L Ranger With P/S)
  • Fig. 16: Drive Belt Routing (4.2L Pickup & Van With A/C - 1997)
  • Fig. 17: Drive Belt Routing (4.2L Pickup & Van Without A/C - 1997)
  • Fig. 18: Drive Belt Routing (4.6L Expedition)
  • Fig. 19: Drive Belt Routing (4.6L, 5.4L & 6.8L Pickup & Van With A/C - 1997)
  • Fig. 20: Drive Belt Routing (4.6L, 5.4L & 6.8L Pickup & Van Without A/C - 1997)
  • Fig. 21: Drive Belt Routing (4.9L Pickup & Van With A/C & P/S - 1996)
  • Fig. 22: Drive Belt Routing (4.9L Pickup & Van With P/S - 1996)
  • Fig. 23: Drive Belt Routing (5.0L Explorer & Mountaineer)
  • Fig. 24: Drive Belt Routing (5.0L - 1996 & 5.8L Pickup & Van)
  • Fig. 25: Drive Belt Routing (5.4L Expedition)
  • Fig. 26: Drive Belt Routing (7.3L Diesel)
  • Fig. 27: Drive Belt Routing (7.5L)
• TABLES
  • BELT TENSION ADJUSTMENT SPECIFICATIONS
  • COOLING SYSTEM SPECIFICATIONS

1996-97 ENGINE COOLING

Cooling System Specifications & Drive Belt Routing

BLEEDING

COOLING SYSTEM

Aerostar, Explorer, Mountaineer, Ranger & Windstar

1. Fill cooling system with 50/50 mixture of coolant and water. Pause several minutes for circulation. Fill radiator to filler neck seat. Install radiator cap fully, then back off to first stop.

   WARNING:

   When engine is operating, NEVER remove radiator cap under any conditions. Failure to follow instruction may damage cooling system or engine, or cause personal injury. Always wrap protective material around radiator cap to avoid injury from hot coolant.

2. Turn heater controls to maximum. Start engine and operate at 2000 RPM for approximately 3-4 minutes. Turn engine off. Using a protective rag, carefully remove radiator cap. Add coolant to filler neck seat.
3. Install radiator cap fully, then back off to first stop. Start engine and allow to operate at 2000 RPM until upper radiator hose is warm. Check heater output. Turn engine off. Using a rag, carefully remove radiator cap. Add coolant to filler neck seat if necessary.
4. Tightly install radiator cap. Remove small cap (large cap is for windshield washer reservoir) on coolant recovery reservoir. Add 1.1 Qts. (1L) of 50/50 mixture of water and coolant to reservoir. Install reservoir cap.

Bronco, Pickup & Van

1. To bleed trapped air from cooling system, disconnect heater hose from water pump. Using 50/50 mixture of coolant and water, fill radiator until coolant flows from heater hose fitting at water pump. Reconnect heater hose.
2. Fill radiator until coolant is 1.5" (38 mm) below radiator cap seal. Install radiator cap. Run engine until warm. Turn engine off. Carefully remove radiator cap and check level. Fill as necessary.

Expedition

1. Turn heater controls to maximum and set air discharge to instrument panel vents. Turn blower to high. Fill cooling system with 50/50 mixture of coolant and water. Pause several minutes for circulation. Start engine and allow to idle. While engine is idling, feel for hot air at instrument panel vents. If air discharge remains cool and coolant temperature gauge does not move, coolant level is low.
2. Stop engine and allow it to cool. Top off coolant as necessary. Start engine and allow it to idle until normal operating temperature is reached. Hot air should discharge from instrument panel vents. Coolant temperature gauge should maintain a stable reading in middle of range. Upper radiator hose should feel hot to touch. Stop engine and allow it to cool. Top off coolant as necessary. Check for coolant leaks.

Villager

1. Loosen engine and radiator air relief plugs. Remove heater pipe air relief cap. See Fig. 1. Connect one end of 40" clear, heat resistant hose to heater pipe relief. Fill coolant reservoir to MAX mark and place hose from heater pipe air relief into coolant reservoir. Ensure hose is below coolant level at all times.
2. Slowly add coolant through radiator filler neck, allowing several minutes for air to escape. When coolant starts to drip from radiator air relief plug, close plug. Tighten plug to 15-19 ft. lbs. (20-26 N.m).
3. Continue adding coolant while gently moving upper radiator hose up and down until coolant level no longer drops in filler neck. Place wire under radiator filler cap negative pressure relief valve. See Fig. 2. DO NOT install cap at this time.
4. Start engine and run at 2000 RPM for 10-15 minutes or until lower radiator hose becomes hot. If coolant comes out of engine air relief plug, close plug. Tighten plug to 15-19 ft. lbs. (20-26 N.m). If coolant in radiator neck lowers, add coolant. If coolant overflows filler neck, install radiator cap (with wire installed).
5. Close engine air relief plug if not already done. Stop engine and allow to cool down completely. Refill radiator and reservoir as necessary. Ensure radiator cap (with wire) is installed. Start engine and warm to operating temperature. If engine temperature raises above normal, stop engine and repeat this step.

   NOTE:

   Ensure coolant level in reservoir tank is maintained at MAX mark for the following steps.

6. On vehicles without rear heater, ensure temperature control lever is in full HOT position. Select any fan speed and mode except OFF. Run engine at 3000 RPM for 5 minutes or until outlet air is hot. Repeat this step at least 3 times. Ensure no water noise is present in heater core.
7. On vehicles with rear heater, run engine at 3000 RPM with front temperature control lever in full COLD position. Move rear temperature control lever to full HOT position. Select any fan speed except OFF. Run engine 5 minutes or until rear outlet air is hot.
8. Move rear temperature control lever to full COLD position. Move front temperature control lever to full HOT position. Select any fan speed and mode except OFF. Run engine 5 minutes or until front outlet air is hot. Repeat steps 7) and 8) at least 3 times. Ensure no water noise is present in front or rear heater core.
9. On models equipped with automatic A/C, operate engine at 3000 RPM with front climate control set at 60°F and rear A/C control unit temperature switch to full WARM position and fan on for 5 minutes or until rear outlet air is hot. Turn rear control unit to full COOL position and set front climate control to 90°F until front outlet air is hot. Repeat process at least 3 times until no water noise is heard at heater core.
10. On all models, stop engine. Fill coolant reservoir to MAX mark. Let engine cool down. Remove radiator cap and remove wire from negative pressure valve. Fill radiator as necessary and reinstall radiator cap. Remove hose from heater pipe relief and quickly install cap on pipe. Fill reservoir as necessary and install reservoir cap.

Fig. 1: Locating Air Relief Plug (Villager)
Courtesy of NISSAN MOTOR CO., U.S.A.

Fig. 2: Holding Negative Pressure Relief Valve Open
Courtesy of NISSAN MOTOR CO., U.S.A.

BELT ADJUSTMENT

Inspect belt for fraying. If fraying has occurred, ensure belt and tensioner are aligned properly. See Fig. 3. If tensioner has reached its limit of travel, belt is excessively stretched and replacement of belt is required. If excessive noise is noticed from tensioner or idler, check for possible bearing failure. Belt tension adjustment is not required on vehicles with automatic belt tensioners. DO NOT apply belt dressing or any other additive to belt(s). Ensure belts are properly installed. See Fig. 4-Fig. 27 . See BELT TENSION ADJUSTMENT SPECIFICATIONS table.

Fig. 3: Aligning Serpentine Belt
Courtesy of FORD MOTOR CO.

BELT TENSION ADJUSTMENT SPECIFICATIONS

Application			New Belt Lbs. (kg)	(1) Used Belt Lbs. (kg)
2.3L, 4.0L, 4.2L, 4.6L, 4.9L, 5.0L, 5.4L, 5.8L, 6.8L & 7.3L
All Models			(2)	(2)
3.0L
Aerostar & Ranger			150-190 (68-87)	140-160 (64-73)
Villager
Generator			150-170 (68-77)	130-140 (59-64)
A/C & P/S			140-150 (64-68)	110-130 (50-59)
Windstar			(3)	(3)
3.8L			160-190 (73-87)	130-160 (50-73)
7.5L
W/ Tensioner			(2)	(2)
W/O Tensioner
Alternator & Air Pump			160-200 (73-91)	110-130 (50-59)
(1) Any belt operated for 5 minutes. (2) No adjustment required for serpentine belt with automatic tensioner. Tension is correct if indicator is within limit marks. (3) Information is not available from manufacturer.

DRIVE BELT ROUTING

Drive Belt Routing (2.3L)

Fig. 4: Drive Belt Routing (2.3L Without A/C Or P/S)
Courtesy of FORD MOTOR CO.

Fig. 5: Drive Belt Routing (2.3L With P/S)
Courtesy of FORD MOTOR CO.

Fig. 6: Drive Belt Routing (2.3L With A/C & P/S)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (3.0L Aerostar & Ranger)

Fig. 7: Drive Belt Routing (3.0L Aerostar & Ranger With P/S)
Courtesy of FORD MOTOR CO.

Fig. 8: Drive Belt Routing (3.0L Aerostar & Ranger With A/C & P/S)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (3.0L Villager)

Fig. 9: Drive Belt Routing (3.0L Villager)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (3.0L Windstar)

Fig. 10: Drive Belt Routing (3.0L Windstar)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (3.8L Windstar)

Fig. 11: Drive Belt Routing (3.8L Windstar)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.0L OHV Explorer)

Fig. 12: Drive Belt Routing (4.0L OHV Explorer)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.0L SOHC Explorer)

Fig. 13: Drive Belt Routing (4.0L SOHC Explorer)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.0L Ranger)

Fig. 14: Drive Belt Routing (4.0L Ranger With A/C & P/S)
Courtesy of FORD MOTOR CO.

Fig. 15: Drive Belt Routing (4.0L Ranger With P/S)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.2L Pickup & Van - 1997)

Fig. 16: Drive Belt Routing (4.2L Pickup & Van With A/C - 1997)
Courtesy of FORD MOTOR CO.

Fig. 17: Drive Belt Routing (4.2L Pickup & Van Without A/C - 1997)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.6L Expedition)

Fig. 18: Drive Belt Routing (4.6L Expedition)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.6L, 5.4L & 6.8L Pickup & Van - 1997)

Fig. 19: Drive Belt Routing (4.6L, 5.4L & 6.8L Pickup & Van With A/C - 1997)
Courtesy of FORD MOTOR CO.

Fig. 20: Drive Belt Routing (4.6L, 5.4L & 6.8L Pickup & Van Without A/C - 1997)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (4.9L Pickup & Van - 1996)

Fig. 21: Drive Belt Routing (4.9L Pickup & Van With A/C & P/S - 1996)
Courtesy of FORD MOTOR CO.

Fig. 22: Drive Belt Routing (4.9L Pickup & Van With P/S - 1996)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (5.0L Explorer & Mountaineer)

Fig. 23: Drive Belt Routing (5.0L Explorer & Mountaineer)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (5.0L - 1996 & 5.8L Pickup & Van)

Fig. 24: Drive Belt Routing (5.0L - 1996 & 5.8L Pickup & Van)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (5.4L Expedition)

Fig. 25: Drive Belt Routing (5.4L Expedition)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (7.3L Diesel)

Fig. 26: Drive Belt Routing (7.3L Diesel)
Courtesy of FORD MOTOR CO.

Drive Belt Routing (7.5L)

Fig. 27: Drive Belt Routing (7.5L)
Courtesy of FORD MOTOR CO.

SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

COOLING SYSTEM SPECIFICATIONS

Application					Specification
Coolant Replacement Interval
All Models					30,000 Miles Or 36 Months
Coolant Capacity
Aerostar, Explorer & Ranger
2.3L					7.2 Qts. (6.8L)
3.0L					11.8 Qts. (11.2L)
4.0L
Automatic Transmission
Standard Cooling					7.8 Qts. (7.4L)
A/C & Super Cooling					8.3 Qts. (7.9L)
Manual Transmission					7.8 Qts. (7.4L)
Bronco (1) & Pickup
4.2L (2)					17.3 Qts. (16.4L)
4.6L & 5.4L (2)					19.4 Qts. (18.4L)
4.9L & 5.0L (1)					13.0-15.0 Qts. (12.0-14.0L)
5.8L					15.0-17.0 Qts. (14.0-16.0L)
7.3L					(3) 29.0 Qts. (27.0L)
7.5L					18.0 Qts. (17.0L)
Expedition (2)
4.6L					19.2 Qts. (18.2L)
5.4L					(4)
Van
4.2L (2)					17.3 Qts. (16.4L)
4.9L (1)					17.0 Qts. (16.0L)
4.6L & 5.4L (2)					19.4 Qts. (18.4L)
5.0L (1)					20.0 Qts. (19.0L)
5.8L
Standard Cooling					20.0 Qts. (19.0L)
A/C Or Super Cooling					23.0 Qts. (20.0L)
6.8L (2)					(4)
7.3L					(3) 31.0 Qts. (29.0L)
7.5L					28.0 Qts. (22.0L)
Villager
With Rear Heater					12.8 Qts. (12.1L)
Without Rear Heater					11.4 Qts. (10.7L)
Windstar					12.1 Qts. (11.5L)
Pressure Cap
Econoline & Pickup (1)					(4)
Expedition & Pickup (2)					16 psi (1.1 Kg/cm2 )
Explorer, Mountaineer & Ranger					13-18 psi (.9-1.3 kg/cm2 )
Villager					12-16 psi (.8-1.1 kg/cm2 )
Windstar					16-18 psi (1.1-1.3 kg/cm2)
All Other Models					13 psi (.9 kg/cm2 )
Thermostat Opens
All Models (Except Villager)
Starts					180-195°F (82-91°C)
Fully Open					200-215°F (93-102°C)
Villager
Starts					180°F (82°C)
Fully Open					195°F (91°C)
(1) For 1996 model year only. (2) For 1997 model year only. (3) Includes 5 Qts. (4.7L) in coolant reservoir bottle. (4) Information is not available from manufacturer.