Cooling System Burp Procedure

[fastblackmerc]

FORD 4.6L DOHC REFILL/BURP PROCEDURE
This procedure is based on a collaboration of information from the forums, the Ford TSB and personal experience. I’ve only included what I feel is relevant in order to refill the system properly as quickly as possible. The general concept here is that air will accumulate at the highest point in the system which is the crossover tube.

1) Car must be parked level or on a slight incline with the front higher is even better.

2) Remove the radiator reservoir cap and crossover plug.


(The crossover plug is normally removed with a ¼” socket drive but is frequently found to be seized. You can damage your ratchet if you apply too much force to remove it. It may be necessary to use a pair of vice grips around the edge of the plug and, in extreme cases, heat it with a torch. I recommend the use of anti-seize or grease on the crossover plug threads upon reinstallation. It is never necessary to tighten the crossover plug much, just snug it, there is an O-ring to seal the system.)

3) Fill the reservoir just past the full line. It is best to add antifreeze (3/4 gal is about 20% concentration) or any additives at this time. Cap the reservoir and you should not need to open the reservoir again. In fact ALWAYS CHECK AND FILL THE SYSTEM AT THE CROSSOVER PLUG after verifying the reservoir is full. (Warning: Do not rely on the reservoir bottle to degas the system or indicate coolant level. The reservoir may show normal level even when there is a large amount of air in the system. There have been those who have lost engines due to not adding coolant at the crossover plug.)

4) Get a funnel and wrap some tape around the tip in order to make a seal with the crossover tube opening. Screw the funnel down into the crossover threads until the funnel seats in firmly.

5) With the reservoir capped, continue adding coolant at the funnel until the funnel fills up an inch or two. Squeeze the upper radiator hose a few times to force air pockets out of the piping.

6) Turn the heater temp control to hot. Start the engine and let it idle but occasionally rev the engine a bit to dislodge any trapped air. Add coolant to keep the funnel full if necessary. You will notice many large air pockets escaping at first but eventually the level will rise in the funnel as temperature goes up expanding the coolant. Keep the engine running just until the thermostat starts to open a bit. (About 170-172° with our thermostat) When this happens the upper radiator inlet will be warm to the touch. (It is normal for tiny air bubbles to still be escaping out of the funnel- this happens because the system is open and unpressurized.)

7) Shut off the engine but be ready to add coolant because the level in the funnel may drop as soon as you do so. Quickly unscrew and remove the funnel, top off the coolant and reinstall the crossover plug only snug. (This is done to keep coolant from being expelled because stagnant coolant in the engine becomes heated and starts expanding again) A common mistake is to run the engine too long which creates excessive heat and, instead of dropping, the coolant level rises in the funnel when the engine is shut off. If this happens just reinstall the plug quickly to minimize coolant loss.

8) After 40 min to an hour the engine will still be warm. Slowly remove the crossover plug but use caution because there may still be a little pressure in the system. Top off the coolant again but this time do not reinstall the plug.

9) After 3 to 5 more hours the engine will be completely cooled down and you will need to top off the crossover once more. Reinstall the crossover plug then verify that the reservoir is full. DO NOT OPEN THE RESERVOIR CAP WITH THE CROSSOVER PLUG REMOVED.

10) You may drive the vehicle normally. Make sure the engine reaches full operating temperature. Best to do some highway cruising and/or the engine should see some mid-rpm speeds at minimum.

11) Later or the next day when the vehicle is completely cold again: Do not start the car and do not open the reservoir. Just top off the coolant at the crossover again. If you have to add more than an ounce or two of coolant then repeat this step again after another heat cycle. (For those who want to get every bit of air out you can repeat this step a few times until you can add only a capful of coolant.)

Web link: http://www.reischeperformance.com/refill.html

[fastblackmerc]

Can this be a sticky???

[345HP87SSAC]

Thanks for this..........

[marauderthis]

FB you have some history at this forum and seen quite a bit hypothetically out of 100 MM owners how many would you say unknowingly inflicted long term damage to their engine?

Its a High percentage right?














FORD 4.6L DOHC REFILL/BURP PROCEDURE
This procedure is based on a collaboration of information from the forums, the Ford TSB and personal experience. I’ve only included what I feel is relevant in order to refill the system properly as quickly as possible. The general concept here is that air will accumulate at the highest point in the system which is the crossover tube.

1) Car must be parked level or on a slight incline with the front higher is even better.

2) Remove the radiator reservoir cap and crossover plug.


(The crossover plug is normally removed with a ¼” socket drive but is frequently found to be seized. You can damage your ratchet if you apply too much force to remove it. It may be necessary to use a pair of vice grips around the edge of the plug and, in extreme cases, heat it with a torch. I recommend the use of anti-seize or grease on the crossover plug threads upon reinstallation. It is never necessary to tighten the crossover plug much, just snug it, there is an O-ring to seal the system.)

3) Fill the reservoir just past the full line. It is best to add antifreeze (3/4 gal is about 20% concentration) or any additives at this time. Cap the reservoir and you should not need to open the reservoir again. In fact ALWAYS CHECK AND FILL THE SYSTEM AT THE CROSSOVER PLUG after verifying the reservoir is full. (Warning: Do not rely on the reservoir bottle to degas the system or indicate coolant level. The reservoir may show normal level even when there is a large amount of air in the system. There have been those who have lost engines due to not adding coolant at the crossover plug.)

4) Get a funnel and wrap some tape around the tip in order to make a seal with the crossover tube opening. Screw the funnel down into the crossover threads until the funnel seats in firmly.

5) With the reservoir capped, continue adding coolant at the funnel until the funnel fills up an inch or two. Squeeze the upper radiator hose a few times to force air pockets out of the piping.

6) Turn the heater temp control to hot. Start the engine and let it idle but occasionally rev the engine a bit to dislodge any trapped air. Add coolant to keep the funnel full if necessary. You will notice many large air pockets escaping at first but eventually the level will rise in the funnel as temperature goes up expanding the coolant. Keep the engine running just until the thermostat starts to open a bit. (About 170-172° with our thermostat) When this happens the upper radiator inlet will be warm to the touch. (It is normal for tiny air bubbles to still be escaping out of the funnel- this happens because the system is open and unpressurized.)

7) Shut off the engine but be ready to add coolant because the level in the funnel may drop as soon as you do so. Quickly unscrew and remove the funnel, top off the coolant and reinstall the crossover plug only snug. (This is done to keep coolant from being expelled because stagnant coolant in the engine becomes heated and starts expanding again) A common mistake is to run the engine too long which creates excessive heat and, instead of dropping, the coolant level rises in the funnel when the engine is shut off. If this happens just reinstall the plug quickly to minimize coolant loss.

8) After 40 min to an hour the engine will still be warm. Slowly remove the crossover plug but use caution because there may still be a little pressure in the system. Top off the coolant again but this time do not reinstall the plug.

9) After 3 to 5 more hours the engine will be completely cooled down and you will need to top off the crossover once more. Reinstall the crossover plug then verify that the reservoir is full. DO NOT OPEN THE RESERVOIR CAP WITH THE CROSSOVER PLUG REMOVED.

10) You may drive the vehicle normally. Make sure the engine reaches full operating temperature. Best to do some highway cruising and/or the engine should see some mid-rpm speeds at minimum.

11) Later or the next day when the vehicle is completely cold again: Do not start the car and do not open the reservoir. Just top off the coolant at the crossover again. If you have to add more than an ounce or two of coolant then repeat this step again after another heat cycle. (For those who want to get every bit of air out you can repeat this step a few times until you can add only a capful of coolant.)

Web link: http://www.reischeperformance.com/refill.html

[slickster]

Should be a sticky. Common simple problem that could be deadly

[Bob Mathis]

Thanks I will be changing all my hoses and do a cooling mod when it cools off around here. Car is parked for now.

[BeeDamn]

That's should be sticky for sure, Thankx Jim I think I have to buy a Delete kit for the COT and say goodbye to burping the cooling system.

[lji372]

That's should be sticky for sure, Thankx Jim I think I have to buy a Delete kit for the COT and say goodbye to burping the cooling system.

There is one other option $$$$$$$ :D

[rsdunphy]

FORD 4.6L DOHC REFILL/BURP PROCEDURE
This procedure is based on a collaboration of information from the forums, the Ford TSB and personal experience. I’ve only included what I feel is relevant in order to refill the system properly as quickly as possible. The general concept here is that air will accumulate at the highest point in the system which is the crossover tube.

1) Car must be parked level or on a slight incline with the front higher is even better.

2) Remove the radiator reservoir cap and crossover plug.


(The crossover plug is normally removed with a ¼” socket drive but is frequently found to be seized. You can damage your ratchet if you apply too much force to remove it. It may be necessary to use a pair of vice grips around the edge of the plug and, in extreme cases, heat it with a torch. I recommend the use of anti-seize or grease on the crossover plug threads upon reinstallation. It is never necessary to tighten the crossover plug much, just snug it, there is an O-ring to seal the system.)

3) Fill the reservoir just past the full line. It is best to add antifreeze (3/4 gal is about 20% concentration) or any additives at this time. Cap the reservoir and you should not need to open the reservoir again. In fact ALWAYS CHECK AND FILL THE SYSTEM AT THE CROSSOVER PLUG after verifying the reservoir is full. (Warning: Do not rely on the reservoir bottle to degas the system or indicate coolant level. The reservoir may show normal level even when there is a large amount of air in the system. There have been those who have lost engines due to not adding coolant at the crossover plug.)

4) Get a funnel and wrap some tape around the tip in order to make a seal with the crossover tube opening. Screw the funnel down into the crossover threads until the funnel seats in firmly.

5) With the reservoir capped, continue adding coolant at the funnel until the funnel fills up an inch or two. Squeeze the upper radiator hose a few times to force air pockets out of the piping.

6) Turn the heater temp control to hot. Start the engine and let it idle but occasionally rev the engine a bit to dislodge any trapped air. Add coolant to keep the funnel full if necessary. You will notice many large air pockets escaping at first but eventually the level will rise in the funnel as temperature goes up expanding the coolant. Keep the engine running just until the thermostat starts to open a bit. (About 170-172° with our thermostat) When this happens the upper radiator inlet will be warm to the touch. (It is normal for tiny air bubbles to still be escaping out of the funnel- this happens because the system is open and unpressurized.)

7) Shut off the engine but be ready to add coolant because the level in the funnel may drop as soon as you do so. Quickly unscrew and remove the funnel, top off the coolant and reinstall the crossover plug only snug. (This is done to keep coolant from being expelled because stagnant coolant in the engine becomes heated and starts expanding again) A common mistake is to run the engine too long which creates excessive heat and, instead of dropping, the coolant level rises in the funnel when the engine is shut off. If this happens just reinstall the plug quickly to minimize coolant loss.

8) After 40 min to an hour the engine will still be warm. Slowly remove the crossover plug but use caution because there may still be a little pressure in the system. Top off the coolant again but this time do not reinstall the plug.

9) After 3 to 5 more hours the engine will be completely cooled down and you will need to top off the crossover once more. Reinstall the crossover plug then verify that the reservoir is full. DO NOT OPEN THE RESERVOIR CAP WITH THE CROSSOVER PLUG REMOVED.

10) You may drive the vehicle normally. Make sure the engine reaches full operating temperature. Best to do some highway cruising and/or the engine should see some mid-rpm speeds at minimum.

11) Later or the next day when the vehicle is completely cold again: Do not start the car and do not open the reservoir. Just top off the coolant at the crossover again. If you have to add more than an ounce or two of coolant then repeat this step again after another heat cycle. (For those who want to get every bit of air out you can repeat this step a few times until you can add only a capful of coolant.)

Web link: http://www.reischeperformance.com/refill.html

thank you very much, I have forwarded this to the shop

[jfernandezs]

Thank you! I will try it tomorrow

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[HotRaud90]

Can this be a sticky???I, too, vote to sticky this write up.

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[a_d_a_m]

I, too, vote to sticky this write up. It already is.

[jfernandezs]

What's does sticky mean?

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[HotRaud90]

It already is.

Doh! Should've checked the dates on this resurrected thread...


What's does sticky mean?

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Sticky means that it's pinned to the top of the forum so it's readily available for people to see. Commonly-asked questions, procedures, and write-ups are usually sticky'd so people have easy access and don't have to go searching for them within the forum.

[CBT]

What's does sticky mean?

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Really? No takers? Not a single "ask yer sister" or "bend over, I'll show ya"?

[Joe Walsh]

Really? No takers? Not a single "ask yer sister" or "bend over, I'll show ya"?How 'bout a TWSS!...?

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[justbob]

Really? No takers? Not a single "ask yer sister" or "bend over, I'll show ya"?

I bit my tongue. I wouldn’t be able to stop... Where’s Joe? He should have a better answer on sticky things.


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[CBT]

No doubt, he would have a totally inappropriate picture of both "burping your system" and "sticky".


I bit my tongue. I wouldn’t be able to stop... Where’s Joe? He should have a better answer on sticky things.


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[jfernandezs]

Thank you.. I tried it yesterday and so far so good.. the heater is heating and the Marauder looks like is not overheating. I just need to do the last step and hope is all good.

Thanks again,

J

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[daniel.drives]

So I did this a couple days ago, in addition to replacing my water pump and thermostat, and I ended up draining about a gallon and a half and putting in 2.25 gallons. I guess whoever had my car before me didn't bother with this, and that's probably why my temp gauge would occasionally rise a bit, which is why I replaced the pump an thermostat in the first place!

[Brentster]

I had a lower radiator hose that was leaking and this thread really helped me out, I basically had the front end up quite a bit. I rolled the car off the lift and had the front tires on the ramp going onto the lift. It was a success, a few hours later I added about 8 ounces of coolant, and then a few days later about 4 ounces of coolant. I checked it a week later and I have not had to add any coolant.

[itsgreenmoney]

I’m in need of help removing the cross over plug. Seems to be seized up!


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[RubberCtyRauder]

Heat, will need new o ring.

[justbob]

I’m in need of help removing the cross over plug. Seems to be seized up!


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Or if you haven’t rounded it out yet it’s surprising just how handy a Milwaukee 1/4” impact is at knocking a little corrosion loose.


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[03Merc]

I’m in need of help removing the cross over plug. Seems to be seized up!


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Channel Locks worked everytime for Me.


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[fastblackmerc]

I’m in need of help removing the cross over plug. Seems to be seized up!


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I can get you a stainless steel replacement with a hex head.

PM me.

[Pantera]

I did this procedure and I was only able to get about 1 and 1/2 gallons in. When I drained it I probably got about 3 and 1/2 gallons out. Did I do something wrong?

[03Merc]

I did this procedure and I was only able to get about 1 and 1/2 gallons in. When I drained it I probably got about 3 and 1/2 gallons out. Did I do something wrong?

I always let the car sit over night and refill from the cross over tube till full.


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[Joe Walsh]

It also helps if you have the front of the car lifted.....front wheels on ramps, up on jackstands or in my case, an inclined driveway.
That helps to purge all the air out of the COT fill pipe.

[blazen71]

Squeeze all the hoses too

[TonyD]

my private messages never seem to work....sorry figured this might work to get a hold of fastblackmerc
ive tried private messages and emails via site but they never show in my sent folder so not sure they are going through can you try to send me a message fastblackmerc to see if it works coming in just not going out. I was just wondering if he was able to fix my bulbs in the eatc

[SilverPhoenix]

my private messages never seem to work....sorry figured this might work to get a hold of fastblackmerc
ive tried private messages and emails via site but they never show in my sent folder so not sure they are going through can you try to send me a message fastblackmerc to see if it works coming in just not going out. I was just wondering if he was able to fix my bulbs in the eatc

Somewhere in the settings there's a way to set it up so your sent messages show up in your folder...I don't remember how as I did this years ago.