Ford Mustang (1999-2004) Service Manual: Bypass Tube - 3.8L

Material

Item Specification
Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) (yellow color) WSS-M97B51- A1

Removal and Installation

1. Drain the engine coolant. For additional information, refer to Cooling System Draining, Filling and Bleeding in this section.

2. Remove the upper intake manifold. For additional information, refer to Section.

3. Remove the bypass hose from the bypass tube.

Bypass Tube - 3.8L

4. Remove the bolt and remove the bypass tube from the coolant pump.

Bypass Tube - 3.8L

5. Disconnect the quick connect fitting and remove the bracket bolts and the bypass tube.

Bypass Tube - 3.8L

6. Install a new O-ring seal on the coolant bypass tube.

Bypass Tube - 3.8L

7. CAUTION: Do not cut the O-ring seal during tube installation or engine coolant leakage may occur.

Clean the O-ring sealing surface on the cylinder heads and lubricate the O-ring seal. Use premium engine coolant.

8. To install, reverse the removal procedure.

Bypass Tube - 3.8L

    Thermostat - 4.6L(4V)
    Material Item Specification Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) (yellow color) WSS-M97B51- A1 Removal and Installation 1. With the vehicle in ne ...

    Bypass Tube - Cobra
    Material Item Specification Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) (yellow color) WSS-M97B51- A1 Removal and Installation 1. Drain the engine coola ...

    Other materials:

    Pinpoint Tests
    The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the s ...

    Inspection and Verification
    1. Road test. Verify the customer's concern by performing a road test on a smooth road. 2. Inspect tires. Check the tire pressure with all normal loads in the vehicle and the tires cold. For additional information, refer to the vehicle certification ...

    Vacuum Hose Repair - Mini-Tube
    Special Tool(s) Vacuum Pump Kit 416-D002 (D95L-7559-A) or equivalent 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch longer t ...