| Diagnosis and Testing Special Tool(s) | | Pressure Tester, Cooling System 303-396 (24-001 A) | | | Adaptor for 303-396 303-396-09 | General Equipment Ford approved diagnostic tool Inspection and Verification - Verify the customer concern.
- Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart | Mechanical | Electrical | - Coolant leaks
- Gaskets/seals
- Core plug(s)
- Hose(s)/hose joints
- Coolant expansion tank cap and seal(s)
- Coolant expansion tank
- Radiator
- Coolant pump
- Thermostat
- Heater core
- Exhaust gas recirculation (EGR) cooler
| - Fuse(s)
- Wiring harness
- Electrical connector(s)
- Engine coolant temperature (ECT) sensor
- Cooling fan motor
- Cooling fan module
- Powertrain control module (PCM)
- Coolant shut off valve
- Coolant degas shut off valve
| - If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
- If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart | Symptom | Possible Sources | Action | | Loss of coolant | * Coolant expansion tank cap or seal(s). | * CHECK the coolant expansion tank cap for tightness and damage. INSTALL a new coolant expansion cap as necessary. | | * Cooling system. | * INSPECT the cooling system for leaks. CARRY OUT the Pressure Test Component Test in this section. INSTALL new component(s) as necessary. | | * Engine. | * INSPECT the engine, cylinder head, cylinder block and cylinder head gasket.
REFER to: Cylinder Head (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
| | The engine overheats (signs of coolant boiling) | * Air in cooling system. | * BLEED the cooling system.
REFER to: Cooling System Draining, Filling and Bleeding (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
| | * Cooling system does not hold pressure. | * CHECK the coolant expansion tank cap for tightness and damage. INSTALL a new coolant expansion tank cap as necessary. * INSPECT the engine, cylinder head, cylinder block and cylinder head gasket.
REFER to: Cylinder Head (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
| | * Coolant level/condition. | * CHECK the coolant level. REFILL the cooling system as necessary.
REFER to: Cooling System Draining, Filling and Bleeding (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
* CHECK the coolant condition and concentration. If the coolant is contaminated or the concentration is below specifications, drain and refill with new coolant.
REFER to: Cooling System Draining, Filling and Bleeding (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
| | * Radiator grille. | * INSPECT the radiator grille for air restrictions/damage. REPAIR or INSTALL new parts as necessary. | | * Cooling fan motor. | * CHECK the operation of the cooling fan. REFER to Ford approved diagnostic tool. | | * Thermostat. | * CARRY OUT the Thermostat Test Component Test in this section. INSTALL a new thermostat as necessary.
REFER to: Thermostat (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| | * Coolant shut off valve. | * CARRY OUT the Coolant Shut off Valve Test in this section. INSTALL a new coolant shut off valve as necessary.
REFER to: Coolant Shutoff Valve (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| | * Coolant degas shut off valve. | * CARRY OUT the Coolant Degas shut off Valve Test in this section. INSTALL a new coolant degas shut off valve as necessary. | | * Coolant pump. | * REMOVE AND INSPECT the coolant pump/impeller. INSTALL a new coolant pump/coolant pump gasket as necessary.
REFER to: Coolant Pump (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| | * Engine. | * INSPECT the engine, cylinder head, cylinder block and cylinder head gasket.
REFER to: Cylinder Head (303-01E Engine - 1.8L Duratorq-TDCi (Lynx) Diesel, In-vehicle Repair).
| | The engine does not reach normal operating temperature. | * ECT sensor. | * CHECK the engine coolant temperature. REFER to the Ford approved diagnostic tool. | | * Temperature gauge. | * CHECK the instrument cluster engine temperature gauge.
REFER to: Instrument Cluster (413-01 Instrument Cluster, Diagnosis and Testing).
| | * Thermostat. | * CARRY OUT the Thermostat Test Component Test in this section. INSTALL a new thermostat as necessary.
REFER to: Thermostat (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
| Component Tests Pressure Test WARNING:When releasing the cooling system pressure, cover the coolant expansion tank cap with a thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction may result in personal injury. NOTE:If the coolant expansion tank cap is rotated counterclockwise by between 2 and 3 full turns, the pressurized coolant will be vented to the underside of the coolant expansion tank. - Remove the coolant expansion tank cap.
- Install the special tools 303-396 and 303-396-09 to the coolant expansion tank.
- Pressurize the cooling system to the coolant expansion tank cap release pressure.
REFER to: Specifications (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, Specifications).
- Observe the cooling system pressure tester gauge reading for approximately two minutes. The pressure should not drop during this time. If the cooling system holds pressure, INSTALL a new coolant expansion tank cap. If the cooling system does not hold pressure, check the cooling system thoroughly for coolant leaks.
- Check the cooling system by repeating steps 3 and 4 at least twice.
- If a coolant leak cannot be found, check the engine for cylinder leakage. Drain the cooling system. Repair any coolant leaks found and fill and bleed the cooling system as necessary.
REFER to: Cooling System Draining, Filling and Bleeding (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, General Procedures).
Radiator Leak Test, Removed From Vehicle CAUTION:Radiator internal pressure must not exceed 130 kpa (20 psi) or damage may result. Clean the radiator thoroughly before leak testing it, to prevent contamination of the water in the test tank. Leak test the radiator in clean water with 138 kpa (20 psi) air pressure. Check it thoroughly for air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
Coolant Expansion Tank Cap Pressure Test WARNING:When releasing the system pressure, cover the expansion tank cap with a thick cloth to prevent the possibility of coolant scalding, Failure to follow this instruction may result in personal injury. - Remove the coolant expansion tank cap.
- Use water to clean the area of the rubber seal and pressure relief valve. Install the pressure tester and adapter and immerse the coolant expansion tank cap in water .
NOTE:If the plunger of the pump is depressed too quickly, an erroneous pressure reading will result. - Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing, and note the highest pressure reading obtained.
- Release pressure by turning the pressure relief screw counterclockwise. Tighten the pressure relief screw and repeat step 3 at least twice to make sure the pressure test reading is repeatable and within acceptable gauge reading limits of the coolant expansion tank cap.
- If the pressure test gauge readings are not within the acceptable gauge reading limits, INSTALL a new coolant expansion tank cap.
Thermostat Test - Using the datalogger function, SELECT the following sensors (as applicable to the application):
- IAT - intake air temperature (IAT) sensor
- ECT - engine coolant temperature (ECT) sensor
- CHT - cylinder head temperature (CHT) sensor
- LOAD - engine load
- VSS - vehicle speed sensor (VSS)
- RPM - engine speed
- DSRPM - desired engine speed
The IAT sensor output is useful if the engine being tested is cold or after an over-night cold soak. The ECT sensor or CHT sensor and the IAT sensor should either indicate the same value or be within 1 to 2 degrees Celsius of each other. The ECT sensor output is important to display as it indicates the engine warm-up and opening temperature for the thermostat. It will initially indicate a slightly higher reading just before the thermostat opens and then drops back before settling to a near flat line output (see graphic below). B - Thermostat settles into a cyclic open and closure pattern CAUTION:If the ECT sensor output reaches the 120ºC default line under normal cooling system pressure, internal damage may be caused to the engine and a diagnostic trouble code (DTC) will be set in the PCM. The test should be stopped and the cause located and corrected. If the cooling system does not pressurize, the coolant will boil at 100ºC which may also damage the engine. CARRY OUT the Coolant Expansion Tank Cap Pressure Test Component Test in this section. If the Ford approved diagnostic tool only allows the ECT sensor to be displayed in volts, refer to the following table for corresponding Celsius values: | Volts | ºCelsius | | 1.33 | 60 | | 1.02 | 70 | | 0.78 | 80 | | 0.60 | 90 | | 0.46 | 100 | | 0.35 | 110 | | 0.27 | 120 | The CHT sensor output is useful to examine the cylinder head temperature rise during the warm-up cycle and later during the normal light throttle cruise test. This sensor output may vary between vehicles with manual transmission and vehicles with automatic transmission and should be used for reference only. The LOAD display is used for reference as it is necessary to maintain a stable load line during the test. It is necessary to carry out the test under normal light throttle cruise driving conditions and average loads, typically 40% to 70% of the load value. The VSS output is used for reference but can help to identify misfires and sensors which fail during the warm-up cycle. The RPM display indicates the engine speed and can be compared with the DSRPM. The DSRPM is the desired or calculated idle speed which the PCM commands the engine to reach. If the thermostat opens too early (before the correct opening temperature has been reached), the engine will not reach this value. When using the Ford approved diagnostic tool in data logger mode, the signals recorded should remain within the DEFAULT values set by the Ford approved diagnostic tool. -
WARNING:Make sure that the Ford approved diagnostic tool is placed in the vehicle so that it does not interfere with the safe operation of the vehicle. Do not place the Ford approved diagnostic tool in the deployment path of any air bag. Failure to follow these instructions may result in personal injury. NOTE:The road test is best carried out with the aid of another technician in the vehicle to enable the vehicle to be driven safely while the sensor outputs are monitored within datalogger. If there is only one technician available, the Ford approved diagnostic tool can be set up (using the record/capture mode camera icon) before leaving the workshop to record a 16 km (10 mile) test. NOTE:The results from the test are more conclusive if the engine is cold when the test is started. Carry out a road test.
REFER to: Road/Roller Testing (100-00 General Information, Description and Operation).
- Drive the vehicle at a constant throttle opening and set speed until the ECT value settles into a shallow rise and fall signal, close to a straight line. This indicates that the thermostat is functioning correctly.
NOTE:Some thermostats indicate the temperature(s) in Celsius and Fahrenheit. The graphic below shows the location and an example of the opening temperature (88ºC) and fully open temperature (102ºC) of a thermostat. The graphic below shows an alternative method used to show the opening temperature (88ºC) and fully open temperature (112ºC) of a thermostat. NOTE:Generally, most thermostats maintain a coolant temperature between 88ºC (190ºF) and 92ºC (198ºF) although dual stage electric thermostats may increase the coolant temperature up to 100ºC (212ºF) under light engine load conditions. The engine should start cleanly and the ECT value will rise quite quickly with smooth progression. If the ECT signal appears unstable or erratic, the ECT sensor, electrical connector and wiring harness to the PCM need to be visually inspected for damage, chafing or water ingress. The temperature should rise to approximately 90ºC for a thermostat that has an 88ºC value. The signal value will then fall as cooler coolant enters the engine. If the ECT value fails to maintain a constant value and falls back to lower figures, typically between 60ºC (140ºF) and 70ºC (150ºF), the thermostat and its sealing function within the thermostat housing must be checked. - INSTALL a new thermostat.
REFER to: Thermostat (303-03F Engine Cooling - 1.8L Duratorq-TDCi (Lynx) Diesel, Removal and Installation).
- Carry out another road test from step 1 using the same criteria to confirm that the concern has been rectified.
- Using the Ford approved diagnostic tool, clear the PCM keep alive memory (KAM) or electrically erasable programmable read only memory (EEPROM) so that new drive values can be learnt.
Coolant Shut off Valve Test - Remove the coolant shut off valve.
REFER to: Coolant Shutoff Valve (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
- Using a suitable piece of wire, connect the coolant shut off valve pin 2, component side to battery ground.
- Using a suitable fused jumper wire, connect the coolant shut off valve pin 1, component side to battery positive.
- Observe the coolant shut off valve piston. The piston should pull into the valve and return to the extended position when the 12 volt supply is removed. If the coolant shut off valve does not return to the extended position, INSTALL a new coolant shut off valve.
REFER to: Coolant Shutoff Valve (303-03E Engine Cooling - 2.0L Duratorq-TDCi (DW) Diesel, Removal and Installation).
Coolant Degas Shut off Valve - Remove the coolant degas shut off valve.
- Connect a workshop water supply hose to one side of the coolant degas shut off valve coolant pipe connector.
- Using a suitable piece of wire, connect the coolant degas shut off valve pin 2, component side to battery ground.
- Using a suitable fused jumper wire, connect the coolant degas shut off valve pin 1, component side to battery positive.
- Turn on the workshop water supply. No water should flow.
- Remove the 12 volt fused supply. Water should flow thorough the coolant degas shut off valve.
- If no water flows, INSTALL a new coolant degas shut off valve.
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