Ford Falcon. Manual — part 169
303-03-3 Engine
Cooling 303-03-3
DESCRIPTION AND OPERATION
Water Pump
Engine Cooling
A centrifugal-type water pump is mounted on the front
Radiator
of the cylinder block.
The radiators are of the tube and fin-core type with
A vane-type impeller supplies coolant through
the tubes arranged for horizontal coolant flow.
centrifugal action to the water pump oitlet port.
Two header tanks, one at each end of the core
If the pump is found to be faulty remove and discard
provide uniform distribution of the coolant to the
as it is of a sealed unit type which cannot be repaired.
tubes. The radiator outlet port is connected to the
Cooling System
water pump inlet port. The radiator inlet port is
connected to the coolant outlet housing of the engine, The cooling system operates as follows:
thereby permitting coolant circulation through the
Coolant flows through the radiator tubes and is
radiator when the thermostat is open.
cooled by air passing over the cooling fins
Midway down the right hand side radiator header tank
assisted by the radiator electric fans.
is the coolant supply tank feed port, this connects the
Coolant expands as the temperature and
cooling system with the supply tank. The supply tank
pressure rise in the system.
provides a chamber to accommodate the expansion
of the coolant as engine temperature increases.
When the limiting system working pressure is
reached, the pressure relief valve in the supply
A small port is located at the top of the right hand side
cap is lifted from its seat and allows coolant to
tank. It is connected to the top of the supply tank. This
flow through the supply tank overflow channel.
port aids the self purging of air from the cooling
system.
The supply tank cap has a rubber seal on the
underside to prevent leakage.
An oil cooler is located in the radiator outlet
header-tank to cool transmission fluid for automatic
When the system temperature and pressure drop,
transmission vehicles.
the coolant contracts in volume and the pressure
in the radiator is reduced.
A draincock is located at the bottom of the left hand
side tank.
WARNING: Never remove the supply tank cap
The coolant supply tank cap incorporates a 120 kPa
under any conditions while the engine is
(18 psi) pressure relief valve and vacuum valve. For
operating. Failure to follow these instructions
routine coolant level inspections the tank provides a
could result in damage to the cooling system or
quick visual method for determining the coolant level
engine and/or personal injury. To avoid having
without removing the tanks cap.
scalding hot coolant or steam blow out of the
Should the coolant level exceed the capacity of the
supply tank, use extreme care when removing the
header tank it is discharged out the overflow channel. supply tank cap from a hot supply tank. Wait until
The header should not be overfilled.
the engine has cooled, try squeezing the upper
radiator hose to determine if the system is still
With the engine cold the level of coolant in the supply
under pressure. Then wrap a thick cloth around
tank should between the max and min lines on the
the supply tank cap and turn it slowly. Step back
supply tank.
while the pressure is released from the cooling
Electric Fans
system.
When certain all the pressure has been released,
The vehicle is fitted with dual electric fans controlled
turn the supply tank cap (still with a cloth), and
by three relays linked to the PCM module.
remove it.
During service operations, ensure that fan is not
rotated in a direction opposing normal operation as
WARNING: The engine radiator electric fans
this may damage the motor (refer to arrow on fan
may come on at any time without warning.
blade).
Disconnect battery ground cable before servicing
Two operating modes are used (excluding OFF)
- this will clear diagnostic trouble codes and
depending on the status of the three relays
adaptive learning. The vehicle must then be driven
(determined by the PCM module). The different
for 30 mins and idled for 15 mins to relearn.
operating modes provide different cooling capabilities. (suggest using a 9 volt memory minder in the
cigar lighter to retain keep alive memory).
Refer to Wiring Diagrams section for a schematic of
the Fan Control System.
Cooling Maintenance
CAUTION: When the ignition is in the ON
Correct coolant level is essential for maximum
position the fans may start without warning.
circulation and adequate cooling. In addition, for the
cooling system to perform its function it must receive
proper care. This includes maintaining corrosion
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303-03-4 Engine
Cooling 303-03-4
DESCRIPTION AND OPERATION (Continued)
protection, keeping radiator fins clean, and periodic
in toxic amounts on repeated or prolonged skin
inspection of the cooling system for leakage.
contact. To promote the safe handling of coolant
the following precautions should be adhered to:
Use care when removing the supply tank to avoid
injury from escaping steam or hot water.
Maintain adequate ventilation and do not
inhale vapours.
To prevent the build up of rust, sludge and other
foreign material in the cooling system, add the
Must never be taken internally. If accidentally
specified Corrosion Inhibitor at the intervals specified.
swallowed seek medical advice immediately.
If it is found necessary to remove build up of foreign
Avoid skin contact. In the event of accidental
material from the cylinder block or radiator owing to
spillage onto the skin, wash off as soon as
neglect of adding an inhibitor, use the specified
possible. If clothing is splashed it should be
radiator cleaner. Removal of such material restores
removed and washed to avoid prolonged skin
cooling efficiency and avoids over-heating.
contact.
In severe cases where cleaning solvents will not
Avoid spillage on vehicle paint work. Wash off
properly clean the cooling system for efficient
immediately with water.
operation, it will be necessary to use the pressure
flushing method.
Various types of flushing equipment are available. If
pressure flushing is used, make sure the cylinder
head bolts are properly tightened to prevent possible
water leakage into the cylinders.
NOTE: Always remove the thermostat prior to
pressure flushing the engine.
When pressure flushing the engine or radiator, flush in
the reverse direction to normal water flow.
A pulsating or reversed direction of flushing water will
loosen sediment more quickly than a steady flow in
the normal direction of coolant flow.
The pressure applied to the radiator must not exceed
the supply tank cap relief pressure.
The coolant is water plus corrosion inhibitor and
Ethylene Glycol antifreeze (Motorcraft R1-33) Refer to
specifications.
CAUTION: Motorcraft R1-33 is not compatible
with soluble oil or soluble oil based additives, or
leak-stop additives. Do not use these other
additives in the vehicle’s cooling system.
If any of these other additives have been added to the
coolant, the system must be drained and cleaned with
Motorcraft radiator cleaner R1-5 and then thoroughly
reverse flushed before refilling with clean water and
the specified quantity of Motorcraft R1-33. Refer to
“DRAINING AND FILLING THE COOLING SYSTEM”
in this part.
WARNING: Do not remove the coolant supply
cap when the engine is hot. Allow the engine to
cool before removing the cap. Even then use
extreme care when removing the cap; wrap a thick
cloth around the cap and turn it slowly. Step back
while pressure is released from the cooling
system. When sure that all pressure has been
released, using the cloth, remove the cap.
WARNING: Motorcraft R1-33
Anti-Freeze/Anti-Boil Concentrate contains
ethylene glycol and/or other constituents which
are toxic if taken internally and can be absorbed
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303-03-5 Engine
Cooling 303-03-5
DIAGNOSIS AND TESTING
Engine Cooling
Visual Inspection Chart
Special Tool(s)
Mechanical
Electrical
Radiator Cap/Cooling System
Pressure Tester
Damaged hoses.
Circuitry
Available Commercially E 9353
Loose/damaged hose
open/shorted.
(Litchfield Tools)
clamps.
Damaged fan control
Damaged thermostat.
relays
Constant Tension Clamp Tool
Damaged head
Damaged radiator
Drive Belt
gaskets.
electric motor, fan
Available Commercially E 9353
Damaged water
blade and fan shroud
(Litchfield Tools)
pump.
assembly.
Damaged radiator.
Damaged or faulty
Inspection and Verification
Damaged supply tank
PCM.
Damaged heater core.
Open circuit in FAN 2
1. Verify the concern by operating the engine cooling
motor.
system to duplicate the concern.
2. Inspect to determine if one of the following
3. If the concern(s) remains after the inspection,
mechanical or electrical concerns apply:
determine the symptom(s) and proceed to the
following Symptom Chart.
Symptom Chart
Condition
Source
Action
Damaged radiator.
Loss of Engine Coolant
Go to Test A.
Damaged water pump.
Loose/damaged radiator hoses.
Loose/damaged heater hoses.
Damaged heater core.
Damaged engine gaskets.
Damaged supply tank.
Demaged cap relief valve.
Demaged drain cock.
Damaged thermostat.
Engine Overheats
Go to Test B.
Damaged water pump.
Internal engine coolant leak.
Cooling fans inoperative.
Radiator coolant flow obstruction
(internal)
Radiator air flow obstruction (external
fins)
Heater core blocked.
Openings or grille blocked.
Damaged or faulty PCM.
Airlock in system
Engine Does Not Reach Normal
Damaged thermostat.
Go to Test C.
Cooling fans, PCM fault.
Operating Temperature
Low engine coolant.
CHECK bolt torques. Perform pressure
Water pump leaking
Gasket (leak at pump/block interface)
test both statically and dynamically
and visually confirm leak. REPLACE
water pump if necessary.
Perform pressure test both statically
O-Ring (leak at heater tube)
and dynamically and visually confirm
leak. REPLACE O-Ring.
A small amount of weep through this
Weep hole
hole is considered normal and
acceptable. Perform pressure test both
statically and dynamically and visually
confirm leak. REPLACE water pump if
necessary.
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303-03-6 Engine
Cooling 303-03-6
DIAGNOSIS AND TESTING (Continued)
Tests
TEST A : LOSS OF COOLANT
Test Step
Result/Action to Take
A1
CHECK COOLANT LEVEL
Yes
NOTE: If engine is hot, allow engine to cool down before
Go to A2
proceeding.
No
Check coolant level coolant supply tank.
REFILL coolant.
Is coolant level OK?
Go to A2
A2
CHECK FOR VISIBLE LEAKAGE
Engine coolant has an added dye colour that makes the
Yes
coolant an excellent leak detector.
Rectify leak.
Check entire cooling system for visible leakage.
RETEST system.
Is there visible leakage?
No
Go to A3
A3
CHECK SUPPLY TANK CAP
Using a Radiator/Heater Core Pressure Tester test
Yes
radiator cap as outlined in this section.
Go to A4
Did supply tank cap test OK?
No
REPLACE damaged supply tank cap.
RETEST system.
A4
CHECK COOLANT FOR INTERNAL LEAKAGE
Visually inspect coolant in radiator and coolant supply
Yes
tank for signs of transmission or engine oil.
If engine oil is evident, Go to Section
Is oil evident in coolant?
308-03.
If transmission oil is evident, Go to
Section 307-01 or Section 308-03.
No
Go to A5
A5
CHECK ENGINE AND TRANSMISSION FOR COOLANT
Remove oil level indicator from engine and transmission. Yes
Carefully inspect oil level indicator for evidence of
If coolant is in engine, Go to Section
coolant.
303-00.
Is coolant evident?
If coolant is in transmission, Go to
Section 307-01 or Section 308-03.
No
Go to A6
A6
PRESSURE TEST COOLING SYSTEM
Yes
NOTE: Check inside vehicle for possible heater core
Rectify leak.
leakage.
RETEST system.
Using a Radiator/Heater Core Pressure Tester conduct a No
pressure test.
Cooling system is operational at this
Check for any signs of visible leakage.
time.
Is there leakage?
RETEST system.
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