Ford Galaxy / Ford S-MAX. Manual — part 347

warm up phase.

Most of the coolant is passed to the heat exchanger and flows back to the coolant pump via
the exhaust gas recirculation (EGR) cooler.

At a certain coolant temperature, the bypass solenoid valve starts to open and remains
open until the operating temperature of the engine is reached.

As soon as the engine reaches operating temperature, the thermostat is opened and the
bypass solenoid valve closes proportionally in relation to the thermostat.

When the engine is warmed up, the thermostat is wide open, as is the shutoff solenoid
valve, and the bypass solenoid valve is fully closed. The large coolant circuit is open in this
state.

Using a shutoff solenoid valve and a bypass solenoid valve speeds up the warm up phase of
the engine, and a faster temperature rise in the passenger compartment is achieved.

The bypass solenoid valve and the shutoff solenoid valve are controlled by the powertrain
control module (PCM).

Bypass solenoid valve

Description

Wiring harness electrical connector

External seal

Seal

Seal

Solenoid valve

Using a bypass solenoid valve enables the engine to reach operating temperature more
quickly.

According to the value supplied by the PCM, the bypass solenoid valve partly or completely
prevents the coolant flow between the coolant outlet on the cylinder head and the coolant
pump.

It cannot be replaced by itself.

Coolant pump

Description

Item

1

2

3

4

5

Item

Part Number

-

-

-

-

-

Part Number

-

Seal

Coolant pump

The coolant pump is installed on the timing end of the engine and is driven by the timing
belt.

The coolant pump housing is made of an aluminium alloy and is secured with five bolts.

The impeller of the coolant pump is made of plastic.

The joint between the coolant pump and the cylinder block is made using a rubberised
metal gasket.

Radiator fan control

Description

Vehicle battery

Battery junction box

Cooling fan module

PCM

Radiator fan speed is controlled by the radiator fan module as a function of input signals
from the PCM.

The radiator fan module is located on the radiator fan housing.

Communication between the radiator fan module and the PCM is done on the CAN bus using
pulse width modulation.

The cooling fan speed is regulated steplessly.

1

2

Item

1

2

3

4

-

-

Part Number

-

-

-

-

Engine Cooling - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-
TDCi (103kW/140PS) - DW - Engine
Cooling

S-MAX/Galaxy 2006.5 (02/2006-)

Print

Diagnosis and Testing

Special Tool(s)

General Equipment

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 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. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Symptom Chart

Pressure Tester, Cooling System

303-396 (24-001 A)

Adaptor for 303-396

303-396-09

Ford approved diagnostic tool

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)

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

(303-01F Engine - 2.0L

Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).

*

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 (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, 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

(303-01F Engine - 2.0L

Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).

*

*

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 (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, 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 (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, 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

the 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 (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) - DW, Removal and
Installation).

*

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 (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L

*