Ford Galaxy / Ford S-MAX. Manual — part 321

Engine Cooling - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4 -
Engine Cooling

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

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Description and Operation

Description

Coolant expansion tank

Coolant outlet connector

Cooling fan motor and shroud

Radiator

Thermostat housing

Coolant pump

CAUTION: If the coolant concentration is insufficient, low temperature protection and

corrosion resistance will be impaired.
NOTE: Providing the coolant has not been contaminated with other fluids or foreign
material, the robust corrosion resistance properties of this coolant means that it can be
reused after changing an aluminum cooling system component. The concentration should
always be checked and maintained within the specification.

Coolant concentration should be checked through the neck of the coolant expansion tank

Item

1

2

3

4

5

6

Part Number

-

-

-

-

-

-

with a hydrometer. The acceptable range of specific gravity (sg) must be maintained.

The coolant used is an orange colored Motorcraft Super Plus 2000 engine coolant. This is a
non silicated organic acid technology (OAT) coolant that must not be mixed with other
coolant types. For cooling system top up, only use coolant which meets the correct
specification.

Engine Cooling - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4 -
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 leak(s)

Gasket(s) or seal(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)

Wiring harness

Electrical connector(s)

Engine coolant temperature (ECT) sensor

Cooling fan

Powertrain control module (PCM)

Symptom

Possible Sources

Action

Loss of coolant

Hose(s) or

hose joint(s).

*

INSPECT the hoses and hose joints. INSTALL a new

hose(s) as necessary.

*

Radiator.

*

INSPECT the radiator for leaks. CARRY OUT the

Pressure Test Component Test in this section. INSTALL
a new radiator as necessary.

*

REFER to:

Radiator

(303-03A Engine Cooling - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

Coolant pump.

*

INSPECT the coolant pump for leaks. CARRY OUT the

Pressure Test Component Test in this section. INSTALL
a new coolant pump or coolant pump gasket as
necessary.
REFER to:

Coolant Pump

(303-03A Engine Cooling -

2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

*

Thermostat

housing.

*

INSPECT the thermostat housing for leaks. CARRY

OUT the Pressure Test Component Test in this section.
INSTALL a new thermostat housing and thermostat
housing gasket as necessary.
REFER to:

Thermostat - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4

(303-03A Engine Cooling - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

*

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 expansion tank for damage.

INSTALL a new coolant expansion tank as necessary.

*

Heater core.

*

CHECK the heater core for leaks.

*

Engine.

*

INSPECT the engine, cylinder head, cylinder block and

cylinder head gasket. REFER to:

Cylinder Head

(303-01A Engine - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Removal and Installation),

Cylinder Head

(303-01C Engine - 2.3L Duratec-HE

(118kW/160PS) - MI4, Removal and Installation).

*

The engine
overheats (signs
of coolant boiling)

Cooling system

does not hold
pressure.

*

INSPECT the coolant expansion 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

(303-03A Engine Cooling -

2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

INSPECT the engine, cylinder head, cylinder block and

cylinder head gasket. REFER to:

Cylinder Head

(303-01A Engine - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Removal and Installation),

Cylinder Head

(303-01C Engine - 2.3L Duratec-HE

(118kW/160PS) - MI4, Removal and Installation).

*

*

*

Air in cooling

system.

*

BLEED the cooling system.

REFER to:

Cooling System Draining, Filling and

Bleeding

(303-03A Engine Cooling - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, General Procedures).

*

Coolant

expansion tank

*

CHECK the coolant expansion tank cap for tightness

and damage. INSTALL a new coolant expansion cap as

*