Ford Galaxy / Ford S-MAX. Manual — part 339

Engine Cooling - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - Engine
Cooling

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

Print

Description and Operation

Description

Cooling fan motor and shroud

Coolant expansion tank

Thermostat housing

Coolant pump

Radiator

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
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

Item

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Part Number

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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 - 1.8L Duratorq-TDCi
(74kW/100PS) - Lynx/1.8L Duratorq-
TDCi (92kW/125PS) - Lynx - 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)
Cylinder head temperature (CHT) sensor
Cooling fan motor
Cooling fan module
Powertrain control module (PCM)

Symptom

Possible Sources

Action

Loss of coolant

Hose(s)/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).

Water 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

(303-03D Engine Cooling -

1.8L Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, 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 or
thermostat housing gasket as necessary.
REFER to:

Thermostat Housing

(303-03D Engine

Cooling - 1.8L Duratorq-TDCi (74kW/100PS) -
Lynx/1.8L Duratorq-TDCi (92kW/125PS) - Lynx,
Removal and Installation).

*

Coolant

expansion tank
cap or seal.

*

CHECK the coolant expansion tank cap for

tightness. If OK, CARRY OUT the Coolant Expansion
Tank Cap Pressure Test Component Test in this
section.

*

Coolant

expansion tank.

*

INSPECT the seal face on 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

(303-01E Engine - 1.8L

Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, 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

(303-01E Engine - 1.8L

Duratorq-TDCi (74kW/100PS) - Lynx/1.8L
Duratorq-TDCi (92kW/125PS) - Lynx, 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.

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*