From Mechanical Database
- Remove intake and airbox (still shown in car).
- Remove the two screws attach the coil pack bracket to block, two to the EGR tube, and one hidden underneath (shown with a 6" long 1/4" extension, screw is battery tray height). Disconnect harnesses and re-locate the coil pack.
- If any of your hoses look like this, you'll want to remove and replace those later. If you don't have any hose, acquire some from the local auto parts before continuing.
- Below is a view in the engine bay from front drivers fender. In the center of the picture you can see the radiator drain plug. The drain plug is on the driver side of the radiator.
- Remove radiator cap (Make sure the car is cooled off first).
- Drain the coolant. As nice looking as that coolant is in the picture below, it was almost 10 years old. If you're just changing the thermostat, you only need to drain 2-3L. If you're doing a full flush it all comes out.
- Remove thermostat housing. The three bolts are obvious. Clean the head surface. Stuff a CLEAN rag into the water jacket to prevent getting contaminants in your cooling system. Clean using a scraper, emery cloth, wire wheel, etc. Surface should be finger smooth with no significant peaks or valleys. REMOVE RAG.
- Remove the thermostat from the housing.
- Remove the rubber seal.
- Clean the thermostat housing the same way as the head surface. Rinse under clean water to remove any debris.
- Install the new thermostat.
- If the heater core hose has to be replaced there are two options. If it's the larger intake hose, buying the proper fitted hose is required. If it's the sensor/heater line, a piece of 3/4" heater hose works fine. The band has to be cut off in order to install the replacement hose over the nipple.
Re-install the thermostat housing with a new gasket. Install all the hoses and tighten mildly. Re-install the intake, the coil pack, and anything that was removed.
- Once everything has been installed, close the drain plug on the radiator.
- If you're doing a full flush follow the next step. If you just topping off, go to adding coolant.
- Fill with 100% water. Run your vehicle with the rad cap off and the hose running into the rad fill. Let it run for about 5-10 min. Drain the water and re-fill with 100% water until the water removed is clear with little to no debris. Once water drained is clean and clear, drain the water and fill with coolant.
Select a mix based on the area which you live. Usually 50/50 or 60/40 antifreeze/water works best. Seek advice if unsure. For best performance, mix with distilled water opposed to domestic tap water. Domestic water contains a lot of minerals and salts that accelerate the corrosion of various cooling system components.
- Fill the radiator until it's full.
- Let the vehicle run for a few min with the radiator cap off and top up as required with the vehicle running. There will be air bubbles trapped in the block and this will work most of them out. Stop when coolant level stays constant.
- It's not required, but usually good practice to change the radiator pressure cap when you do a coolant change.
- Put the radiator cap on and check that the vehicle reaches operating temperature. Minor fluctuations will occur for the first little while as any remaining air works it's way out.
- Top off the radiator overflow tank.
- Ford Escort & ZX2 section for the entire index of all Ford Escort and ZX2 related articles.