How to Get the Air Out After Thermostat Work in a Windstar

Before 1995, Ford only offered its customers one minivan choice, the Aerostar, and it did not look much like any minivan of the era. In 1995, Ford Chyslerized its minivan, by basically making a minivan that fit the same mold as the popular Chrysler lineup of minivans: short, rounded nose, front-wheel drive and a car-like ride. Each model year throughout the entire nine-year production life, the Windstar always had two engine options, a 3.0-liter V-6 and a 3.8-liter V-6. In the entire production life of the Windstar, there were two different bleeding processes -- the process of eliminating air from the cooling system. The 1995 through 1998 models used a more difficult process than the 1999 through 2003 models.

Instructions

Fill the two empty clean, sealable one-gallon containers halfway with new Ford Premium Cooling System Fluid, or equivalent coolant meeting Ford specification ESE-M97B44-A. This makes a total of four half-gallons of antifreeze. Fill the four half-full containers of coolant the rest of the way with clean water. This creates a total of four gallons of coolant with the recommended 50-50 mix of coolant and water.

Open the radiator cap and fill the radiator with the 50-50 mix of coolant until the level reaches the base of the radiators filler neck. Wait five minutes to let the coolant work its way through the system and fill any air pockets in the radiator. The coolant level will drop as the coolant displaces the air. Refill the radiator to the bottom of the filler neck again with the 50-50 mixture of coolant.

Tighten the radiator cap on the radiator. Unscrew the cap from the coolant overflow tank and fill it to the Full Cold mark with the 50-50 coolant mix. Add 1 quart of full-strength Ford Premium Cooling System Fluid to bring the coolant level to just above the Full Cold mark.

Start the engine and allow it to idle until the upper radiator feels warm roughly five minutes.

Shut off the engine and wait about five minutes. Slowly remove the radiator cap, using a thick shop rag as an insulator for your hand, and add the 50-50 coolant mix until the fluid level reaches the bottom of the radiators filler neck.

Tighten the radiator cap and the coolant overflow tank cap. If your Windstar has only a front heater, this completes the process. If your Windstar has dual heaters, you have four more steps.

Start the engine and set the heater control to its hottest setting. Change the airflow controls so the heat comes out of the dashboard vents. Allow the vehicle to continue idling until the temperature gauge reaches near the middle of the Normal range.

Stop the engine and allow it to sit until the engine feels cool to the touch.

Using plastic locking pliers, pinch the heater hose running to the main heater core in the firewall and lock them into place. Unscrew the cap from the coolant overflow tank and add coolant until it reaches the Full Cold mark.

Start the engine and allow it to idle until the temperature reaches the midway point in the Normal range; the locking pliers force coolant back to the auxiliary heater core. Remove the plastic locking pliers. Turn the heater on and verify that there is heat from the front and rear heater. If there is no heat, repeat the process from Step 8.

Unscrew the coolant overflow tank cap and fill the overflow tank to just above the Cold Full range with the 50-50 mix of coolant.

Move the temperature control and the fan speed to the Max setting. Start the engine and allow it to idle until the temperature reaches the midway point of its temperature gauge. Add more 50-50 coolant mix to the coolant overflow bottle, as needed.

Increase the engine speed to about 3,000 rpm and hold it there for 15 seconds, then let the engine return to an idle. Allow the engine to idle for one minute. Repeat this step four times.

Shut the engine off and allow the vehicle to sit until the engine is cool to the touch. Fill the coolant overflow bottle to the Cold Fill range with 50-50 coolant mix. Tighten the coolant overflow cap back onto the overflow tank.