Ford Falcon. Manual — part 170

303-03-7 Engine

Cooling 303-03-7

DIAGNOSIS AND TESTING (Continued)

TEST B : ENGINE OVERHEATS

Test Step

Result/Action to Take

B1

CHECK COOLANT LEVEL

Yes

NOTE: If engine is hot, allow engine to cool down before

Go to B2

proceeding.

No

Remove supply tank cap and check coolant level at

REFILL coolant.

supply tank.

Go to A

Is coolant level OK?

B2

CHECK COOLANT CONDITION

Check coolant for contaminants such as rust or corrosion. Yes

Also check for fluid discoloration.

Go to B3

Is coolant condition OK?

No

FRETEST system.LUSH system.

B3

CHECK FOR AIRFLOW OBSTRUCTION

Visually inspect A/C condenser core and radiator core for Yes

obstructions such as leaves or bugs.

REMOVE obstruction and

Is there any obstruction?

CLEAN A/C condenser core and

radiator.

RETEST system.

No

Go to B4

B4

CHECK HEATER CORE OPERATION

Install supply tank cap.

Yes

As engine starts to warm up, feel the inlet and outlet

Go to B5

heater water hoses. They should feel the same after three No

or four minutes.

TURN engine OFF before it

Is outlet heater water hose the same temperature as

overheats. SERVICE heater core.

the inlet heater water hose?

RETEST system.

B5

CHECK WATER THERMOSTAT OPERATION

Allow engine to run for 10 minutes.

Yes

Feel the inlet and outlet heater water hoses and the

REPLACE water thermostat.

underside of the upper radiator hose.

RETEST system.

Are the upper radiator hose and heater water hoses

No

cold?

Leave engine RUNNING.

Go to B6

B6

CHECK COOLING FAN

Refer to Cooling Fan Self Test in this section.

TEST C : ENGINE DOES NOT REACH

NORMAL OPERATING TEMPERATURE

Test Step

Result/Action to Take

C1

CHECK ENGINE TEMPERATURE

Start engine and allow to RUN for 15 minutes.

Yes

Feel inlet and outlet heater water hoses and underside of

REPLACE water thermostat.

upper radiator hose.

RETEST system.

Are upper radiator hose and heater water hoses cold? No

CHECK coolant temperature gauge

for correct operation.

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303-03-8 Engine

Cooling 303-03-8

DIAGNOSIS AND TESTING (Continued)

foreign material between the gasket and cap

Pressure Test

body. Refer to supply tank Cap Cleaning and

It is recommended that a cooling system pressure test

Inspection. Rinse supply tank cap in clean water.

gauge be used to properly test the system for:

NOTE: The supply tank cap used on this system is

Blown or leaking cooling system sealing gaskets.

unique; replace only with the proper supply tank cap.

Internal or external coolant leakage.

2. Replenish the engine coolant at the supply tank.

Pressure cap malfunction.

3. Install the supply tank cap.

Many types of pressure gauges are available for use.

Therefore, it is recommended that the gauge

Cooling Fan Self Test - All Models

manufacturer’s instructions be followed when

The cooling fan motors and circuits are tested during

performing the test.

a PCM KOEO TEST. Refer to Section 303-14

NOTE: Never exceed the rated pressure indicated on Powertrain Control Module.

the pressure cap when performing the pressure test.

Fan

Relay 1 Relay 2 Relay 3 Fan 1

Fan 2

Speed

Supply Tank Cap Pressure Test

OFF

OFF

OFF

OFF

OFF

OFF

1. Remove the supply tank cap.

LO

ON

OFF

OFF

LOW

LOW

2. Use water to clean the cap seal and the vacuum

HI

ON

ON

ON

HIGH

HIGH

relief valve.

3. Install the cap on a pressure test unit following the

manufacturer’s directions.

4. Slowly depress the plunger of the test unit pump

until the highest reading is achieved on the

gauge.

5. This reading should be within the specification for

the cap being tested.

6. Repeat the test several times. If the gauge

reading is not within specification replace the cap.

Thermostat Test

Thermostat Removed

Remove the thermostat and immerse it in boiling

water. Remove when open and place a .05 mm feeler

gauge in the throat of the thermostat and allow the

thermostat to cool and clamp on the feeler gauge.
Suspend a thermometer into a container of cool water

and heat the water.
Suspend the thermostat by the feeler gauge into the

container of warming water. When the thermostat

opens and drops off the feeler gauge, note the

temperature.
Refer to Specifications in this section for the operating

temperatures and opening dimensions.
If the problem being investigated is insufficient heat,

the thermostat should be checked for leakage. This

may be done by holding the thermostat up to a lighted

background. Slight leakage of light at one or two

locations on the perimeter of the valve may be

detected. This should be considered normal.

Coolant System

In the event no engine coolant is observed in the

supply tank, or when a coolant level change does not

occur, check the system as follows:
1. With the engine cold, remove the supply tank cap,

and inspect the filler neck sealing gasket for

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303-03-9 Engine

Cooling 303-03-9

GENERAL PROCEDURES

ESE-M97B44-A / WSS-M97B51-A1. Ford R1-33

Coolant Level Check

meets this specification and is green in colour.

The coolant level is maintained by a coolant supply

1. Inspect the coolant color:

tank located on the right hand fender apron just

If Engine Coolant R-33 or equivalent meeting

ahead of the suspension tower. If there is no coolant

Ford specification ESE-M97B44-A has a

visible in the supply tank the procedure quoted under

clear, light green or blue color, this indicates

‘DRAINING AND FILLING THE COOLING SYSTEM’

higher water content than required.

must be used.

Dark brown could indicate unauthorized

Do not remove coolant supply tanks pressure cap for

stopleak may have been used. Flush the

routine coolant level inspections. The coolant supply

system and refill with the correct mixture of

tank provides a quick visual method for determining

water and Premium Engine Coolant.

the coolant level without removing the pressure gap.

With the engine cold, the level of the coolant supply

A light or reddish brown color indicates that

tank should be between the MIN and MAX lines on its

rust may be present in the cooling system.

side wall.

An iridescent sheen on top of the coolant

could indicate a trace of oil is entering the

WARNING: Do not attempt to remove the

system. For additional information on engine

supply tank cap under any circumstances while

diagnosis, refer to Diagnosis in this section.

the engine is operating or while the engine is hot.

A milky brown color may indicate that either

To do so might lead to damage to the cooling

engine oil or transmission fluid is entering the

system and the engine and could result in serious

cooling system. If transmission fluid is

personal injury from hot coolant or steam

suspected the cause may be a leaky radiator,

blowout. Switch off the engine and wait until it has

pressure test the cooling system. For

cooled. Use extreme care when removing the cap

additional information, refer to component

and wrap a thick cloth around the cap and turn it

tests in this section. If engine oil is suspected

slowly. Step back while the pressure is released

the cause of the leak may be internal to the

from the cooling system. When you are sure all

engine. For additional information on engine

the pressure has been released – still with a cloth

diagnosis, refer to Diagnosis in this section.

– turn cap and remove it.

If transmission fluid is contaminated with

NOTE: The level of the coolant in the supply tank

engine coolant the cause may be a leaky

should only be checked when the engine is cold.

radiator, pressure test the system. For

additional information, refer to the component

Remove the supply tank cap.

tests in this section.

Fill the supply tank to the FULL/MAX mark with

2. If engine coolant appearance is good, test the

specified coolant.

engine coolant range with the battery and

Refit the supply tank cap correctly (fully tighten by

antifreeze tester:

hand).

Maximum range is 50/50.

NOTE: If the coolant tank requires topping up to

Minimum range is 33/67.

maintain the correct level of coolant, the complete

cooling system should be checked without delay.

3. Adjust coolant range and level if necessary:

If coolant is low, add specified coolant mixture

NOTE: When topping up the cooling system a mixture

only.

of clean drinkable water and Motorcraft R1-33

inhibitor should be used. Adding water only will dilute

If the engine coolant tests to weak, add

the inhibitor and reduce its effectiveness. Refer to

straight engine coolant concentrate until the

specifications.

readings are within acceptable levels.
If the engine coolant tests strong, remove

Cooling Color Inspection

some of the engine coolant and add water

until the readings are within acceptable levels.

CAUTION: Check the coolant level, engine oil NOTE: Use only clean drinkable water In the engine

and transmission fluid, top off the coolant if

cooling system. It is strongly recommended that in

needed, if there is engine coolant in the engine oil areas of heavily mineralised water (e.g. bore water),

or transmission fluid the cause must be corrected only non-mineralised water (e.g. rain water) is used.

and oil/fluid changed or major component damage Mineral deposits on cooling surfaces will reduce the

may occur.

effectiveness of an engine cooling system and lead to

The initial factory coolant fill is a 33% by volume

engine overheating.

mixture of glycol-based anti-freeze/ant-corrosion

inhibitors in water, meeting Ford specification

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303-03-10 Engine

Cooling 303-03-10

GENERAL PROCEDURES (Continued)

2. Place a suitable container below the radiator

Adjusting Anti — Freeze Protection

draincock. The front bumper “lower air deflector”

Level

has a drainage aperture adjacent to the radiator

draincock and doesn’t need removal.

NOTE: All vehicles are factory supplied with 33%

concentration of R1-33 anti-freeze, which provides

Open the draincock or remove lower radiator

protection to -16 C.

hose and allow to drain.

The specific gravity of the coolant should be checked

Close the radiator draincock when finished.

at the recommended service intervals and the

To Refill

concentration adjusted by adding either, anti-freeze

alone, a mixture of anti-freeze and water or water

1. Refit the lower radiator hose or drain plug.

alone, depending on whether the specific gravity is

2. Add the specified amount of anti-freeze to the

low, correct or high. The specific gravity is checked

coolant supply tank.

using an anti-freeze tests hydrometer with the coolant

3. Fill the system with clean water to the “ADD/MIN”

cold.

mark on the supply tank.

Example: Checking a 50-50 concentration of

NOTE: CAPACITY: Includes heater and coolant

Motorcraft R1-33 anti-freeze (1.080 coolant specific

pressure bottle.

gravity).

Most service refills are about 80 percent of

If the hydrometer reading is 1.080 or greater, no

capacity listed. This is because not all coolant is

adjustment is necessary.

drained the cooling system.

If the reading is less than 1.080, add R1-33 to the

4. Install the cap one turn only or depress and turn

cooling system at the rate of 1 litre for each 0.012

until fully locked.

S.G. increase required (e.g. 1.068 to 1.080).

5. Set the heater control to ‘HOT’(for an Automatic

NOTE: Draw of sufficient coolant to allow for the

Climate Control system set the temperature to

addition of the required quantity of R-133.

32

°C).

NOTE: The heater control doesn’t require setting

Anti — Freeze Replacement

to hot as the heater core is constantly flowing

coolant.

NOTE: The cooling system should be drained, flushed

with clean water and refilled with water and

6. Start the engine and run it at 2000 rpm for 10

anti-freeze according to the recommendations given in

minutes to open the thermostat and purge air from

the Specifications section of this Section.

the system.

Vehicles must be refilled using specified quantities of

7. Top up the supply tank to the “FULL/MAX” mark.

R1-33 in the cooling system.

8. Replace the cap.
9. Refit the lower air deflector. This procedure must

Draining and Filling the Cooling

be followed to ensure correct system

System

performance.

Draining

Radiator Cleaning

WARNING: To avoid personal injury, do not

Condition of driving - Town, City and Casual

unscrew the coolant pressure relief cap while

Driving

engine is operating or hot. The cooling system is

1. Loosen the top two radiator mounting brackets.

under pressure; steam and hot liquid can come

NOTE: Cleaning of the radiator exterior is

out forcefully when the cap is loosened slightly.

important to obtain maximum radiator efficiency

Failure to follow these instructions may result in

and cooling performance.

personal injury.

2. Tilt the radiator and fan assembly rearwards from

CAUTION: The coolant must be recovered in

the top.

a suitable, clean container for reuse. If the coolant

3. Use air pressure line to clear the debris then

is contaminated it must be recycled or disposed

wash by using a hose (pressure cleaning is too

of correctly.

aggressive) between radiator and condenser. Do

NOTE: About 80% of coolant capacity can be

not point the nozzle near the radiator and

recovered with the engine in the vehicle. Dirty, rusty

condenser fins as this may damage them.

or contaminated coolant requires replacement.

4. Reposition radiator. Refer to the Radiator

1. Release the pressure in the cooling system by

removal/installation in this section for additional

slowly turning the pressure relief cap one half turn

information.

counterclockwise. When the pressure is released, Condition of driving - Outback, Dirt and Field

remove the pressure relief cap.

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