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Section 03-01D: Diesel Engine, 7.3L V-8
1992 Bronco/Econoline/F-Series Workshop Manual
REMOVAL AND INSTALLATION
Please rate highly if this helps. this is 1992, only thing I have, should be the same.
A poppet-type thermostat is used with the engine. When the thermostat is closed, coolant flows to the water pump through a bypass passage at the front of the engine. When the thermostat is open, coolant flows through the coolant outlet elbow (thermostat housing) to the radiator.
CAUTION: Replacement thermostats other than the specified Motorcraft or Navistar thermostats may result in engine overheat damage. The specified thermostat does not contain an internal bypass, since the by-pass is located in the cylinder block. Therefore, whenever the thermostat is replaced, it is mandatory that only Motorcraft E5TZ-8575-C or Navistar 1807945-C1 thermostat be installed.
The thermostat is a high temperature thermostat for use with a mixture of water and permanent-type antifreeze.
CAUTION: Do not attempt to repair the thermostat. It should be replaced if it is not operating properly.
Check the thermostat before installing it, following the procedure described in this section.
Thermostat Design (Acceptable vs. Unacceptable)
Disconnect ground cables from both batteries.
NOTE: On vehicles equipped with EEC, when the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the EEC processor relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
Drain coolant from radiator until coolant level is below thermostat. Refer to Section 03-03, Engine Cooling.
Loosen and remove alternator and vacuum pump drive belts.
Remove alternator. Position alternator out of the way.
Remove vacuum pump and bracket. Position pump out of the way.
Remove all but the lowest alternator/vacuum pump mounting casting bolt. Loosen the lowest bolt and pivot the alternator/vacuum pump casting outboard.
Remove the water outlet housing attaching bolts. Bend the radiator upper hose upward and remove the thermostat and gasket.
Inspect thermostat as outlined in this section.
Clean the water outlet housing gasket surfaces. Coat a new outlet housing gasket with Perfect Seal Sealing Compound B5A-19554-A (ESR-M18P2-A) or equivalent. Position the water outlet housing gasket on intake manifold opening.
Install thermostat in crankcase opening with the copper pellet or element toward engine and the thermostat flange positioned in the recess. If thermostat is improperly installed, it will cause a restricted flow of coolant.
Position the water outlet housing against the crankcase. Install and tighten the attaching bolts to specification listed at the end of this section.
Reposition the alternator/vacuum pump casting. Install attaching bolts.
Install vacuum pump with bracket and tighten to specification. Refer to Section 03-05, Accessory Drive.
Install alternator and drive belt.
Install vacuum pump drive belt.
Adjust alternator and vacuum pump drive belts to specification. Refer to Section 03-05, Accessory Drive.
Fill and bleed the cooling system. Refer to Section 03-03, Engine Cooling.
Connect ground cables to both batteries.
Operate the engine until normal operating temperature is reached, then check the coolant level. Inspect cooling system for leaks.
WARNING: DO NOT STAND IN LINE WITH OR NEAR RADIATOR FAN WHEN REVVING ENGINE.
From the top of the car remove the slide and anchor bolt from the alternater bracket. remove your 3 or 4 pin plug and diconnect the pos power line beside the 3 or 4 pin plug ( on the back of the alternater). now raise the car and from below remove the lower bolt that allows the alternater to swing back and forth. the bolt fits through the housing of the alternater. remove the belt. now the alternater is free. this lower bolt that was just removed attaches to a bracket bolted to the block. remove this bracket and the alternater will slide out of the bottom of the car. complete the above steps in reverse to install new part.
Relieve alternator tension by releasing tension on the belt (it's the A/C pulley you get to it from inside the drivers wheel well), Remove the bolts holding the alternator to the bracket on the block, remove the two bracket bolts on the block and remove the bracket. Loosen the two bracket arms (marked L and R) of the top of the radiator and push the radiator forward about two inches, you will now have enough clearance to get the alternator out of the top (where the radiator was). Easy Peasy. Good luck!
the only way to really remove it is to take it out from the bottom, but get ready for a project. The only way to take it out of the bottom is to take the drive axle out, luckily you do not have to take it out of the transmission though. Good luck
once the car is jacked up, the wheel is removed, and the wiring is disconnected loosen the pivot bolt(14mm) on the bottom(it can't be removed with the alternator in place) and remove the top bolt(12mm). some prying will be needed to break it loose and swivel. now, if the car is supported with stands sufficiently and jacked up high enough you should be able to squat somewhat into the wheel well and grab the alternator with both hands. have a pry bar handy as well if you do not already have one and pry on the pivot ear a bit and get the alternator to swivel. once it breaks loose you should be able to swivel it, pry it, swivel it, pry it and so on. lifting it up and to the left and it should work it's way out. it will take a bit of effort at first and the car will rock some, hence the need for added support. I had a bottle jack and 2 jack stands for a more secure base.
DISCLAIMER: it's never completely safe to do anything with the car on a jack or stands so caution must be taken. if you aren't comfortable with this method I suggest a mechanic.
back to the repair.. once you get the alternator up out of the slot bracket then you should be able to turn the alternator for clearance and remove it with a fair amount of ease. I turned mine counter-clockwise for clearance. all instructions are taken as given the battery negative cable has been disconnected, the belt has been removed from the pulley and you are at the point to work directly with the alternator.
you have to remove the alternator and the bracket that holds the alternator. When you remove the bracket be very careful. the inlet and outlet for the heater core run through this bracket. Once you remove the 3 bolts holding it you'll need to work it back and forth as you pull. Do not try to pry or force it because you'll break off the outlet pipe that leads in to the engine block. The pipe is sealed with an o-ring. If it's real stubborn shoot a little wd-40 on it and that should help make it easier to pop out.