Ford Galaxy / Ford S-MAX. Manual — part 333

Engine Cooling - 2.5L Duratec
(162kW/220PS) - VI5 - Engine Cooling

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

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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

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

Engine coolant temperature (ECT) sensor

Heater core

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

(303-03E 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.

*

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

(303-03C Engine Cooling

- 2.5L Duratec (162kW/220PS) - VI5, 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 Housing

(303-03C Engine

Cooling - 2.5L Duratec (162kW/220PS) - VI5,
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

(303-01D Engine - 2.5L

Duratec (162kW/220PS) - VI5, 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 (303-03 Engine Cooling - 2.5L Duratec-
ST (VI5), General Procedures).

*

Radiator grille.

*

INSPECT the radiator grille for air restrictions or

damage. REPAIR or INSTALL new parts as
necessary.

*

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.

*

Coolant level or

condition.

*

CHECK the coolant level. REFILL the cooling

system as necessary.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling - 2.5L Duratec-
ST (VI5), General Procedures).

CHECK the coolant condition. If the coolant is in

poor condition drain and refill with new coolant.
REFER to: Cooling System Draining, Filling and
Bleeding (303-03 Engine Cooling - 2.5L Duratec-
ST (VI5), General Procedures).

*

*

Coolant

concentration.

*

REFER to: Specifications (303-03 Engine Cooling

- 2.5L Duratec-ST (VI5), Specifications).

*

Cooling system

does not hold
pressure.

*

INSPECT the coolant expansion tank for damage.

INSTALL a new coolant expansion tank as
necessary.

*

Cooling fan.

*

CHECK the operation of the cooling fan. REFER to

the Ford approved diagnostic tool.

*

Thermostat.

*

CARRY OUT the Thermostat Test Component Test

*

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 ½ a full turn, the
pressurized coolant will be vented to the underside of the coolant expansion tank cap.

1. 1. Slowly remove the coolant expansion tank cap to release the cooling system

pressure.

2. 2. Install the coolant expansion tank cap.

3. 3. Install the special tools 303-396 and 303-396-09 to the coolant expansion tank.

4. 4. Pressurize the cooling system to the coolant expansion tank cap release pressure.

REFER to: Specifications (303-03 Engine Cooling - 2.5L Duratec-ST (VI5),
Specifications).

5. 5. 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.

in this section. INSTALL a new thermostat as
necessary.
REFER to: Thermostat (303-03 Engine Cooling -
2.5L Duratec-ST (VI5), Removal and Installation).

Coolant pump.

*

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

(303-03C Engine Cooling

- 2.5L Duratec (162kW/220PS) - VI5, Removal
and Installation).

*

Thermostat.

*

CARRY OUT the Thermostat Test Component Test

in this section. INSTALL a new thermostat
housing and thermostat housing gasket as
necessary.
REFER to: Thermostat (303-03 Engine Cooling -
2.5L Duratec-ST (VI5), Removal and Installation).

*

Engine.

*

INSPECT the engine, cylinder head, cylinder block

and cylinder head gasket.
REFER to:

Cylinder Head

(303-01D Engine - 2.5L

Duratec (162kW/220PS) - VI5, Removal and
Installation).

*

The engine does not
reach normal
operating
temperature.

Thermostat.

*

CARRY OUT the Thermostat Test Component Test

in this section. INSTALL a new thermostat as
necessary.
REFER to: Thermostat (303-03 Engine Cooling -
2.5L Duratec-ST (VI5), Removal and Installation).

*

Cooling fan.

*

CHECK the operation of the cooling fan. REFER to

the Ford approved diagnostic tool.

*

The cooling fan is
inoperative

Cooling fan.

*

CHECK the operation of the cooling fan. REFER to

the Ford approved diagnostic tool.

*

6. 6. Check the engine for coolant leaks. 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 (303-03 Engine Cooling -
2.5L Duratec-ST (VI5), General Procedures).

7. 7. Recheck the cooling system by repeating Steps 3 and 4 at least twice.

Radiator Leak Test, Removed From Vehicle

CAUTION: Radiator internal pressure must not exceed 138 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 130 kpa (18 psi) air pressure.
Check it thoroughly for air leaks. INSTALL a new radiator if necessary.
REFER to:

Radiator

(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 Expansion Tank Cap Pressure Test

WARNING: When releasing the cooling system pressure, cover the coolant expansion

tank cap with a thick cloth.

1. 1. Remove the coolant expansion tank cap.

2. 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 .

NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure
reading will result.

3. 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. 4. 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.

5. 5. If the pressure test gauge readings are not within the acceptable gauge reading

limits, INSTALL a new coolant expansion tank cap.

Thermostat Test

1. 1. Connect the

Ford approved diagnostic tool

to the data link connector (DLC).

2. 2. Using the Ford approved diagnostic tool 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