Engine Cooling - Diagnosis and Testing

	HD Antifreeze Coolant 3-Way Test Kit 328-2050-62291 or equivalent
	Coolant/Battery Refractometer ROB75240 or equivalent
	Pressure Tester STN12270 or equivalent
	UView Combustion Leak Tester UVU560000-R

NOTICE: Use the correct coolant. Do not mix coolant types. Mixing coolant types may reduce the corrosion protection of the coolant and may damage the engine or cooling system. For the correct coolant for this vehicle, refer to Specifications.

Diagnostic Trouble Code Chart

Refer to: Engine Cooling System Safety Precautions (100-00 General Information, Description and Operation).

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

PCM Diagnostic Trouble Code Chart

Inspection and Verification

1. 1
   Verify the customer concern.
2. 2
   Visually check the engine coolant level in the coolant recovery reservoir when the system is cold.
3. 3
   Make sure the pressure relief cap is installed correctly.
4. 4
   Record all cooling system diagnostic trouble codes (DTCs). Refer to the PCM DTC Chart in this section for DTC descriptions.
5. 5
   If the cooling system is filled correctly and no fail-safe cooling related DTCs are retrieved, verify the customer concern by starting the engine to duplicate the condition.
6. 6
   Visually check for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

1. 1
   If the inspection reveals an obvious concern that can be readily identified, correct as necessary.
2. 2
   Inspect the condition of the coolant.
   

   1. Check the color of the coolant.
      
      • A darker orange color with debris may indicate that a commercially available stop-leak product may have been used. This may result in loss of coolant flow to critical engine components. If sediment is present, flush the system and refill with the correct mixture of distilled water and the appropriate Motorcraft® Concentrated Antifreeze/Coolant.
        Refer to: Engine Cooling System Flushing (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, General Procedures).
      • A light or reddish-brown color indicates the presence of rust in the cooling system. Flush the system and refill with the correct mixture of distilled water and the appropriate Motorcraft® Concentrated Antifreeze/Coolant.
        Refer to: Engine Cooling System Flushing (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, General Procedures).
      • A rainbow sheen on the coolant surface may indicate oil contamination in the system. For engine diagnosis,
        Refer to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
        Flush the system and refill with the correct mixture of distilled water and Motorcraft® Concentrated Antifreeze/Coolant. Refer to: Engine Cooling System Draining, Vacuum Filling and Air Bleeding (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, General Procedures).
      • A milky brown color may indicate that engine oil has entered the cooling system. Pressure test the cooling system. Refer to the component tests in this section. If engine oil is suspected, the leak may be inside the engine. For engine diagnosis,
        REFER TO: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
        Flush the system and fill with the appropriate mixture of distilled water and Motorcraft® concentrated antifreeze/coolant. REFER TO: Engine Cooling System Draining, Vacuum Filling and Air Bleeding (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, General Procedures).

   2. If the appearance of the engine coolant is acceptable, check the Engine Coolant/Battery Coolant Freezing Point Range with a refractometer. Maintain the coolant concentration.
      REFER TO: Specifications (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Specifications).

   3. If necessary, adjust the coolant range and level:
      
      • If the coolant level is low, add only the specified coolant mixture.
      • If the engine coolant is too weak, remove some engine coolant and add Motorcraft® concentrated antifreeze/coolant until the readings are within the acceptable limits.
      • If the engine coolant is too strong, remove engine coolant and add distilled water until the readings are within the acceptable limits.
3. 3
   If an obvious cause for an observed or reported concern is found, correct the cause and verify proper system operation before proceeding to the next step.

Symptom Chart

The diagnosis in this manual assumes a certain level of skill and knowledge of Ford-approved diagnostic procedures.
REFER TO: Diagnostic Methods (100-00 General Information, Description and Operation).

Pinpoint Tests

Coolant Loss

Normal Operation and Failure Conditions

The engine cooling system is a closed system that accommodates coolant expansion and contraction and pressure changes as the coolant heats up and cools down during engine operation. Various gaskets, seals, hoses and clamps keep the coolant in the cooling system and keep other fluids and contaminants out of the cooling system. Coolant loss may be caused by either external or internal leaks anywhere within the cooling system.

Possible Sources

• Coolant Hoses or Tubes
• Clamps
• Thermostat Housing
• Thermostat Housing O-rings
• Coolant Pump Gasket
• Radiator
• Charge Air Cooler Radiator
• Charge Air Cooler
• Charge Air Cooler Coolant Pump
• Pressure Relief Cap
• Coolant Pump
• Turbocharger (may leak internally or externally)
• Oil Cooler (internal or external leakage possible) (if equipped)
• Heater Core
• Engine Gaskets (internal or external leakage possible)
• Transmission Oil Cooler (may leak internally or externally)
• Degas bottle
• Transmission Fluid Warmer Control Valve
• Transmission Fluid Warmer (internal or external leakage possible)
• Engine Block Core Plugs
• Cylinder Head Core Plugs
• Engine Block Heater (if equipped)

WARNING: Always allow the engine to cool before opening the cooling system. Do not remove the coolant pressure relief cap while the engine is running or the cooling system is hot. The cooling system is under pressure; steam and hot coolant can be expelled forcefully when the cap is loosened. Failure to follow these instructions may result in serious injury.

A1 INSPECT AND VERIFY

Inspect and verify. Is there a concern? Yes REPAIR as necessary. No GO to A2

A2 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE ENGINE COOLING SYSTEM

Ignition OFF. Visually check the engine coolant level in the degas bottle and adjust if necessary. Pressure test the engine cooling system. Refer to Component Tests, Cooling System Pressure Test in this section. Is there an external leak in the engine cooling system? Yes REPAIR or INSTALL new components. No GO to A3

A3 CHECK THE CHARGE AIR COOLER

Remove the charge air cooler from the intake manifold. REFER TO: Charge Air Cooler (CAC) (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation). CHECK the CAC for leaks. Is there a concern? Yes INSTALL a new CAC. REFER TO: Charge Air Cooler (CAC) (303-12A Intake Air Distribution and Filtering - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation). No GO to A4

A4 CHECK THE ENGINE COOLANT FOR INTERNAL LEAKAGE

Inspect the engine coolant in the degas bottle for signs of engine oil. Is engine oil visible in the engine coolant? Yes REFER TO: Engine (303-00 Engine System - General Information, Diagnosis and Testing). No GO to A5

A5 CHECK THE ENGINE OIL FOR COOLANT CONTAMINATION

Remove the engine oil dipstick. Is engine coolant visible in the engine oil? Yes REFER TO: Engine (303-00 Engine System - General Information, Diagnosis and Testing). No GO to A6

A6 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID CONTAMINATION

Check the engine coolant in the degas bottle for signs of transmission fluid. Is transmission fluid visible in the engine coolant? Yes INSTALL a new transmission fluid cooler. REFER TO: Transmission Fluid Cooler - 1.5 L EcoBoost (118 kW/160 L PS) - I4/2.5 L Duratec (110 kW/150 L PS) (307-02A Transmission Cooling - 6-Speed Automatic Transmission - 6F35, Removal and Installation). and INSTALL a new transmission fluid warmer. REFER TO: Transmission Fluid Warmer (307-02A Transmission Cooling - 6-Speed Automatic Transmission - 6F35, Removal and Installation). REPAIR the transmission, if necessary. REFER TO: Automatic Transmission - 1.5 L EcoBoost (118 kW/160 L PS) - I4 (307-01A Automatic Transmission - 6-Speed Automatic Transmission - 6F35, Diagnosis and Testing). CHECK the system for normal operation. No GO to A7

A7 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT CONTAMINATION

Remove the transmission fluid level plug. Check the transmission fluid for engine coolant contamination. Is engine coolant visible in the transmission fluid? Yes INSTALL a new transmission fluid cooler. REFER TO: Transmission Fluid Cooler - 1.5 L EcoBoost (118 kW/160 L PS) - I4/2.5 L Duratec (110 kW/150 L PS) (307-02A Transmission Cooling - 6-Speed Automatic Transmission - 6F35, Removal and Installation). INSTALL a new transmission fluid warmer. REFER TO: Transmission Fluid Warmer (307-02A Transmission Cooling - 6-Speed Automatic Transmission - 6F35, Removal and Installation). REPAIR the transmission, if necessary. REFER TO: Automatic Transmission - 1.5 L EcoBoost (118 kW/160 L PS) - I4 (307-01A Automatic Transmission - 6-Speed Automatic Transmission - 6F35, Diagnosis and Testing). CHECK the system for normal operation. No GO to A8

A8 CHECK THE COOLING SYSTEM FOR EXHAUST GAS

Using the Cooling System Combustion Gas Tester, follow the instructions supplied with the tester, check the engine coolant for combustion gases. Are combustion gases present? Yes REFER TO: Engine (303-00 Engine System - General Information, Diagnosis and Testing). No The cooling system is operating normally.

Engine Overheats

Normal Operation and Failure Conditions

The engine cooling system maintains engine temperature during operation. Correct coolant flow through the engine, radiator and other cooling system passages and components is necessary to maintain correct engine temperature.

The engine coolant flows mainly from the engine to the radiator circuit and back to the coolant pump. Coolant is supplied from the coolant pump through the cylinder block and cylinder heads. A separate circuit from the engine also supplies coolant to the heater core. The coolant pump circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat opens, coolant flows through the radiator circuit to transfer heat generated by the engine to the outside air.

Engine overheating normally occurs when the ability to control any coolant flow at the correct rate is disrupted, when heat cannot be transferred from the engine through the coolant (including engine oil), or when heat generated by the engine cannot be transferred to the outside air through the radiator.

Possible Sources

• Active Grille Shutter
• Low coolant level
• Engine coolant external leakage
• Air trapped in the system
• Pressure relief cap installation
• Restricted airflow through the A/C condenser/radiator
• Engine coolant internal leakage
• Coolant condition/concentration
• Non-OEM engine enhancement components
• Electric cooling fan
• ECT Sensor
• Radiator
• Thermostat
• Temperature Gauge
• Coolant Pump
• Restricted coolant flow

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

Engine Does Not Reach Normal Operating Temperature

Normal Operation and Failure Conditions

The engine cooling system maintains engine temperature during operation. Correct coolant flow through the engine, radiator and the remainder of the cooling system passages and components is essential to maintain correct engine temperature.

Engine coolant flows mainly from the engine to the radiator circuit and back to the coolant pump. Coolant is supplied from the coolant pump through the cylinder block and cylinder heads. A separate circuit from the engine also supplies coolant to the heater core. The coolant pump circulates the coolant. The coolant thermostat is a coolant-operated control valve that responds to coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat opens, coolant flows through the radiator circuit to transfer engine heat to the outside air.

A concern that the engine does not reach normal operating temperature typically occurs when coolant flow through certain circuits (radiator, heater core) is greater than expected for the conditions. The heat exchangers cannot be built into the engine, because they remove too much heat, including the radiator, heater core and oil cooler. In addition, a concern that the engine does not reach normal operating temperature may be related to low coolant level or trapped air that prevents hot coolant from reaching the heater core, an inoperative climate control system, or concerns perceived or related to an incorrect engine temperature sensor indication.

Possible Sources

• Low coolant level
• Thermostat
• ECT Sensor
• Temperature Gauge

Diagnostic Trouble Code (DTC) Fault Trigger Conditions

WARNING: Always allow the engine to cool before opening the cooling system. Do not remove the coolant pressure relief cap while the engine is running or the cooling system is hot. The cooling system is under pressure; steam and hot coolant can be expelled forcefully when the cap is loosened. Failure to follow these instructions may result in serious injury.

C1 PERFORM INSPECTION AND CHECKS

Complete the inspection and verification procedure described in this section. Were any concerns found? Yes REPAIR as necessary. No GO to C2

C2 CHECK DTC (DIAGNOSTIC TROUBLE CODE) P0125 OR P0128

The ignition is on. Using a scan tool, perform the PCM self-test. Is DTC P0125 or P0128 present? Yes GO to C3 No The cooling system is operating normally. If an ECT sensor concern is suspected, CHECK the ECT sensor operation. REFER TO: Instrument Cluster, Message Center and Warning Chimes (413-01 Instrument Cluster, Message Center and Warning Chimes, Diagnosis and Testing). If a climate control system concern is suspected, CHECK the climate control system operation. For Dual Zone Automatic Temperature Control, REFER TO: Climate Control System - Vehicles With: Dual Zone Automatic Temperature Control (DATC) (412-00 Climate Control System - General Information, Diagnosis and Testing). For Electronic Manual Temperature Control (EMTC), REFER TO: Climate Control System - Vehicles With: Electronic Manual Temperature Control (EMTC) (412-00 Climate Control System - General Information, Diagnosis and Testing). If any other diagnostic trouble codes (DTCs) are present,

C3 CHECK THE COOLANT LEVEL

Visually check the engine coolant level in the coolant recovery reservoir. Is the engine coolant level within specification? Yes GO TO C4 No GO to Pinpoint Test A

C4 CHECK ECT (ENGINE COOLANT TEMPERATURE) SENSOR OPERATION

Using a scan tool, view the PCM PID identifiers. Monitor the ECT temperature PID. Using an infrared temperature gun, measure and record the coolant outlet temperature at the rear of the cylinder head next to the ECT sensor. Is the temperature reading similar to the ECT PID value? Yes INSTALL a new thermostat. REFER TO: Thermostat Housing (303-03A Engine Cooling - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation). No INSTALL a new ECT sensor. REFER TO: Engine Coolant Temperature (ECT) Sensor (303-14A Electronic Engine Controls - 1.5 L EcoBoost (118 kW/160 L PS) - I4, Removal and Installation).

Component Tests

Cooling System Pressure Test

1. 1
   TURN the engine OFF.
2. 2
   Check the engine coolant level and adjust as necessary.
3. 3
   Remove the coolant recovery reservoir cap. Inspect the coolant recovery reservoir cap and reservoir for any conditions that could cause improper sealing, such as cross-threading, burrs, a damaged O-ring, etc. If any concerns are found, INSTALL a new cap and/or coolant recovery reservoir.
4. 4
   Attach the pressure tester and adapter (Snap-On TA53 or equivalent) to the degas bottle cap. The cap must hold a pressure of 145 kPa +/- 21 kPa (21 psi +/- 3 psi). If any concerns are found, INSTALL a new cap.
5. 5
   Attach the pressure tester and adapter (Snap-On TA52, ACT ASSF3-47, Redline RDL95-0750 or equivalent) to the degas bottle.

NOTICE: Do not pressurize the cooling system above the maximum pressure listed in the Specifications table in this section, or cooling system components may be damaged.

1. 1
   To build pressure in the engine cooling system, slowly pump the pressure tester plunger and increase the pressure to 124 to 138 kPa (18-20 psi). Observe the gauge reading for approximately 2 minutes. The pressure must not drop during this time. If the pressure drops during this time, check for leaks and repair as necessary.
2. 2
   Allow the vehicle to stand for a minimum of 5 hours or overnight.

1. 1
   If the pressure drops more than the expected range of 2-4 psi and no leaks are found, and the pressure continues to drop, an internal engine leak may be present. Check the coolant for engine oil and the engine oil for coolant.
   REFER TO: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
2. 2
   If the pressure does not drop, remove the cooling system pressure tester and adapter from the degas bottle.
3. 3
   Install the degas bottle cap until it contacts the stop.

Thermostat

Install a new thermostat only after performing at least one of the following tests and inspections:

• Precise Test B or C
• Visual Inspection of the Thermostat

Visual Inspection of the Thermostat

1. 1
   Remove the thermostat.
2. 2
   Inspect the thermostat for signs of damage, including:

• Valve not fully seated (light visible through the valve)
• Foreign object lodged in the main valve
• Bent or broken frame or flange
• Bent or broken spring
• Wax leakage from the wax element or a bulge in the element
• Any other damage or distortion

3. If damage is found during the inspection, remove all foreign objects or debris and install a new thermostat.

Radiator Leak Test, Removed from the Vehicle

NOTICE: Never leak test an aluminum radiator in the same tank of water in which copper/brass radiators are tested. Fluxes and caustic cleaners may be present in the tank and will damage the aluminum radiator.

1. Check the radiator for leaks by submerging it in clean water and applying air pressure up to the maximum value specified in the Specifications table.

Charge Air Cooler Radiator Leak Test, Off-Vehicle

NOTICE: Never leak test an aluminum radiator in the same tank of water in which copper/brass radiators are tested. Fluxes and caustic cleaners may be present in the tank and will damage the aluminum radiator.

1. Check the radiator for leaks by submerging it in clean water and applying air pressure up to the maximum value specified in the Specifications table.