cooling system FORD FIESTA 2007 Owner's Guide

Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-1 6V (Sigma)llI4L
3-03A-26 Duratec-I 6V (Sigma)llm6L Duratec-1 6V (Sigma) 303-03A-26
REMOVAL AND INSTALLATION
Radiator(24 254 0) /'
Special Tool@)
I I Remover/lnstaller, Cooling I
2. Push the cooling fan motor and shroud (.
upwards and then downwards to remove.
24003
Removal
Hose Clamp
303-397 (24-003)
1. Disconnect the battery ground cable. For
additional information, refer to
Section 414-01 [Battery, Mounting and
Cables].
5. Using the special tool, disconnect the
2. Drain the cooling system. radiator
upper hose.
For additional information, refer to Cooling
System Draining, Filling and Bleeding in
this section.
3. Disconnect the cooling fan motor and
cooling fan resistor electrical connectors.
4. Remove the cooling fan motor and shroud.
I. Release the cooling fan motor and shroud
from the retaining brackets.
6. Using the special tool, disconnect the
radiator lower hose.
7. Remove the radiator retainers.
1. Remove the radiator retainer locking screws.
2006.0 Fiesta 1212006 ~210041 en
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303-03B-1 Engine Cooling -- 2.OL Duratec-HE (M14) 303-03B-1
SECTION 303-03B Engine Cooling . 2.OL Duratec-HE
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE
SPECIFICATIONS
Specifications
........................................................................\
.............................................. 303-038-2
DESCRIPTION AND OPERATION
Engine Cooling
........................................................................\
...................................... 303-038-3
System Overview
........................................................................\
.................................. 303-038-3
........................................................................\
............................................... Components 303-038-4
........................................................................\
....................................................... Coolant 303-038-7
........................................................................\
....................................... Changing Coolant 303-038-7
Fail-safe Cooling
........................................................................\
........................................ 303-038-8
DIAGNOSIS AND TESTING
........................................................................\
........................................... , Engine Cooling 303-038-9 ........................................................................\
.......................... , Inspection and Verification 303-038-9
Symptom Chart ........................................................................\
........................................... 303-038-9
........................................................................\
........................................ Component Tests 303-038-1 3
GENERAL PROCEDURES
.............................................. Cooling System Draining. Filling and Bleeding (24 1 22 0) 303-038-1
7
Draining
........................................................................\
...................................................... 303-038-1 7
Filling and Bleeding
........................................................................\
.................................... 303-038-1 7
REMOVAL AND INSTALLATION
Coolant Pump
........................................................................\
....................... (24 404 0) 303-038-19
Thermostat Housing
........................................................................\
................................ 303-038-21
Coolant Outlet Connector
........................................................................\
........................... 303-038-24
........................................................................\
.................................. Radiator (24 254 0) 303-038-26
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303-03B-3 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-3
DESCRIPTION AND OPERATION
Engine Cooling
I I
System Overview
Item Description
I 1 I Coolant outlet connector I
1 2 1 Exhaust gas recirculation (EGR) valve I
1 3 1 Cooling fan motor I
1 4 1 Radiator I
Item Description
1 5 1 Oil cooler I
1 6 I Thermostat housing I
2006.0 Fiesta 1212006 G421219en
7
8
Coolant pump
Coolant expansion tank
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303-03B-7 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-7
DESCRIPTION AND OPERATION
Oil Cooler
Item Description
I I I Oil cooler I
1 2 1 Oil filter adaptor I
1 3 1 Oil filter I
The oil cooler is an oil to water type and is a full
flow system.
The oil cooler and oil filter are fitted to an adaptor
which is mounted on the cylinder block.
The coolant supply for the oil cooler is through the
thermostat by-pass hose.
Coolant Recovery System
A pressurized coolant expansion tank system is
used which continuously separates the air from the
cooling system and replenishes the system through
the coolant expansion tank outlet hose.
A continuous vent from the engine and radiator to
I the coolant expansion tank prevents air locks from
forming in the cooling system.
No manual bleed points are provided on the
system. The coolant expansion tank serves
as the location
for:
Service fill.
Coolant expansion during warm-up.
Air separation during operation.
System pressurization by the coolant pressure
cap.
Coolant
A WARN1NG:Coolant contains monoethylene
glycol and other constituents which are
toxic if taken internally and can be
absorbed into the skin after prolonged
contact. Failure to follow this instruction
may result in personal injury.
Coolant concentration should be checked through
the neck of the expansion tank with a hydrometer.
The acceptable range of specific gravity (sg) of
correctly balanced fluids is between
1.06 and
1.07kg/l, which represents a coolant concentration
between 40% and 55%. If the concentration falls
below 40% there is insufficient low temperature
protection and the corrosion resistance will be
inadequate. In such cases the concentration must
be brought back to specification.
The coolant used is the orange-colored Motorcraft
Super Plus 2000. Motorcraft Super Plus 2000 is a
non silicated organic acid technology (OAT)
coolant, and must not be mixed with other coolant
types. For cooling system top up, only use coolant
which meets the correct specification and is
compatible with the existing coolant.
Changing Coolant
A WARN1NG: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.
A CAUTI0N:When draining the coolant or
changing any cooling system components,
it is imperative that no coolant comes into
contact with the camshaft drive belt or
accessory drive belt. If necessary the belt
should be removed. Contamination of the
belt may result in premature belt failure.
N0TE:Providing the coolant has not been
contaminated with other fluids or foreign matter,
the robust corrosion resistance properties of this
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303-03B-8 Engine Cooling - 2.OL Duratec-HE (M14) 303-038-8
DESCRIPTION AND OPERATION
coolant means that it can be re-used after changing If the engine temperature still continues to rise,
an aluminium cooling system component, although
stage
3 of the strategy will commence. This will
the concentration should always be checked and
result in the engine being totally disabled before
(
maintained within specification.
major engine damage or seizure occurs. The MIL .
This coolant should be changed after a period of will begin-to
flash, indicating to the driver that the
10 years or 150 000 miles, whichever occurs first. engine will
be switched off after 30 seconds. This
Refill the cooling system with coolant which meets allows the driver time to choose a suitable parking
the correct specification and is compatible with the place.
existing coolant.
Fail-Safe Cooling
The vehicle has a strategy built into the powertrain
control module (PCM) that will control the engine
if the engine starts to overheat.
If the engine starts to overheat, stage
1 of the
strategy will commence. The ECT sensor transmits
a signal to the PCM which then moves the
temperature gauge pointer into the red zone.
If the engine is not switched off and the
temperature continues to rise, the malfunction
indicator lamp (MIL) is illuminated. This indicates
to the driver that the engine is approaching critical
limits and should stop. At this point DTC
PI285 is
set in the PCM which can be retrieved using WDS.
If the MIL and temperature gauge are ignored by
the driver, stage 2 of the strategy will commence.
The PCM will start to control the engine by cutting
out two cylinders and restricting the RPM to below
3000 RPM. The MIL will remain illuminated. This
indicates that long term engine damage may occur
and vehicle emissions will be affected. At this point
DTC
PI299 is set in the PCM which can be
retrieved using WDS.
Air is drawn into the deactivated cylinders which
helps to control the temperature of the engine
internal components. The deactivated cylinders
are alternated to allow even cooling of all the
cylinders.
N0TE:lf the driver is using a high percentage of
throttle travel (for example, an overtaking
maneuver) when the PCM starts engine
deactivation (stage 2), the deactivation will be
delayed for 10 seconds.
N0TE:After 2-cylinder operation has begun, the
engine will not revert to 4-cylinder operation, even
if the temperature should fall, until the ignition is
switched off and then on again.
N0TE:The MIL can only be extinguished by using
WDS after the fault has been rectified and the DTC
cleared.
2006.0 Fiesta 1212006 G421219en
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303-03B-9 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-9
DIAGNOSIS AND TESTING
.Engine Cooling
' . Special Tool(s)
Pressure Tester, Cooling
System
303-396 (24-001 A)
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
( I or electrical damage. Visual
lns~ection Chart
I Mechanical I Electrical I
Coolant leak(s)
Coolant
level
Gasket(s) or seal(s)
Core plug(s)
Hose(s) or hose
joints
Coolant expansion
tank cap and seal
Coolant expansion
tank
Radiator
Coolant pump
Thermostat housing
Heater core
Accessory drive belt
Coolant outlet
connector
Fuse(s)
Relay(s)
Wiring harness
Electrical
connector(s)
Engine coolant
temperature (ECT) sensor
Cooling fan motor
Powertrain control
module (PCM)
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step
4. If the cause is not visually evident, verify the
symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Symptom
Loss of coolant Possible Sources
Action
Hose(s) or hose joint(s).
Radiator. INSPECT
the hoses and hose
joints. INSTALL a new
hose(s)
as necessary.
INSPECT the radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling
- 2.OL
Duratec-H E (M 14), Removal
and Installation).
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303-03B-11 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-1 I
DIAGNOSIS AND TESTING
Symptom
The engine overheats (signs of
coolant boiling)
Possible Sources Action
Cooling system does not hold
pressure. INSPECT
the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary. INSPECT the coolant pump or
coolant pump gasket for
damage. INSTALL a new
coolant pump or coolant pump
gasket as necessary.
REFER to: Coolant Pump (303-
03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal
and Installation).
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - 1.3L Duratec-8V
(Rocam), In-vehicle Repair). -
Air in cooling system. BLEED the cooling system.
REFER to: Cooling System
Draining, Filling and Bleeding
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
General Procedures).
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.
Coolant expansion tank. INSPECT
the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
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303-03B-12 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-I 2
DIAGNOSIS AND TESTING
Symptom Possible
Sources Action
Coolant level or condition.
Radiator grille.
Coolant pump.
Thermostat. CHECK
the coolant level.
REFILL the cooling system as
necessary.
REFER to: Cooling System
Draining, Filling and Bleeding
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
General Procedures).
CHECK the coolant condition
and concentration
REFER to: Specifications (303-
03 Engine Cooling
- 2.OL
Duratec-HE (M14), Specifica-
tions).
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
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
General Procedures).
INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.
CARRY OUT the Pressure Test
Component Test in this section.
INSPECT the coolant pump for
leaks. INSTALL a new coolant
pump or coolant pump gasket
as necessary.
REFER to: Coolant Pump (303-
03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal
and Installation).
CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
2006.0 Fiesta 1212006 G426582en
REFER to: Thermostat Housing
(303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation). ,,
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Engine Cooling - 2.OL Duratec-HE (M14)
DIAGNOSIS AND TESTING
Symptom Possible Sources
Action
I Accessory drive belt. CHECK the condition of the
accessory drive belt.
REFER to: Accessory Drive
(303-05 Accessory Drive,
Diagnosis and Testing).
Cooling fan.
CHECK the operation of the
I cooling fan. REFER to WDS.
Engine. INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head
(303-
01 Engine - I .3L Duratec-8V
(Rocam), I n-vehicle Repair).
The engine does not reach
normal operating temperature. CHECK the ECT sensor.
I REFER to WDS.
Temperature gauge. CHECK the instrument cluster
engine temperature gauge.
REFER to: lnstrument Cluster
- Vehicles Built Up To:
1012005 (41 3-01 lnstrument
Cluster, Diagnosis and
Testing)
I lnstrument Cluster - Vehicles
Built From:
1012005 (41 3-01
lnstrument Cluster, Removal
and Installation).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat housing and thermostat
housing gasket as necessary.
REFER to: Thermostat Housing (303-03 Engine Cooling
-
2.OL Duratec-HE (M14),
Removal and Installation).
Component Tests
Pressure Test
A 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.
N0TE:lf the coolant expansion tank cap is rotated
counterclockwise by 1 12 a full turn, the pressurized
coolant will be vented to the underside of the
coolant expansion tank cap.
1. Remove the coolant expansion tank cap.
2. Install the special tools 303-396 and 303-396-01
to the coolant expansion tank.
3. Pressurize the system to the coolant expansion
tank cap release pressure.
REFER to: Specifications (303-03 Engine
Cooling
- 2.OL Duratec-HE (M14),
Specifications).
2006.0 Fiesta 1212006 G426582en
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303-03B-14 Engine Cooling - 2.OL Duratec-HE (M14) 303-03B-14
DIAGNOSIS AND TESTING
4. Observe the cooling system pressure tester make sure the pressure test reading
is
gauge reading for approximately two minutes. repeatable
and within acceptable gauge reading
The pressure should not drop during this time. limits of
the coolant expansion tank cap.
( If the system holds Pressure, proceed to Step 5. If the pressure test gauge readings are not 7. If the system does not hold pressure, check
within the acceptable gauge reading limits,
it thoroughly for coolant leaks.
INSTALL a new coolant expansion tank cap.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and fill and bleed the cooling system as
Thermostat Test
necessaw.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling
- 2.OL
Duratec-HE (M14), General Procedures).
.Recheck the system by repeating Steps 3 and
4 at least twice.
Radiator Leak Test, Removed From Vehicle
CAUTI0N: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 (303-03 Engine Cooling
- 2.OL
Duratec-HE (M14), Removal and Installation).
Coolant Expansion Tank Cap Pressure Test
A 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.
1. Remove the coolant expansion tank cap.
2. 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.
N0TE:lf the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result.
3. Slowly depress the plunger of the pressure test
pump until the pressure gauge reading stops
increasing, and note the highest pressure
reading obtained.
4. Release pressure by turning the pressure relief
screw counterclockwise. Tighten the pressure
relief screw and repeat step 3 at least twice to
I. Connect the WDS to the data link connector
(DLC).
2. Using the WDS 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).
Item Description 1'. .
) A 1 Thermostat opens I\
B Thermostat settles into a cyclic open and
I I closure pattern
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