Engine Cooling System: Other Ford Escape III

2.0L GTDI

Note. Red arrows indicate temperatures above 90°C (194°F), yellow arrows indicate temperatures approximately 90°C (194°F), green arrows indicate temperatures below 90°C (194°F).

2.5L

Note. Red arrows indicate temperatures above 90°C (194°F), yellow arrows indicate temperatures approximately 90°C (194°F), green arrows indicate temperatures below 90°C (194°F).

SPECIAL TOOLS 3-Way HD Antifreeze Coolant Test Kit 328-2050-62291 or equivalent Coolant/Battery Refractometer 300-ROB75240 or equivalent Pressure Tester STN12270 or equivalent UView® Combustion Leak Tester UVU560000-R Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware or equivalent scan tool

Scheme 43

Scheme 44

Scheme 45

Scheme 46

MATERIAL SPECIFICATIONS

1.6L GTDI

The 1.6L GTDI engine's cooling circuit consists of an additional engine coolant bypass valve and heater shut-off valve. Using these two valves, the coolant flow through the engine is specifically restricted or stagnated in the warm-up phase. This restriction of the coolant flow makes it possible for the engine components to warm up faster. The result is a significant reduction in the emissions of harmful pollutants and an improvement in fuel economy (i.e. reduced friction) during the warm-up phase. Both solenoid valves are controlled by the PCM.

The following input parameters are used to do this

1. coolant temperature
2. ambient air temperature
3. engine speed
4. engine load
5. status of the air conditioning system

Warm-up regulation is performed in four phases. Phase 1 or 2 occurs after initial engine start-up depending on the ambient air temperature.

Phase 1

During an initial engine start-up with an ambient temperature is 60-75°F (16-24°C) or warmer (calibratable) the heater shut-off valve closes and the engine coolant bypass valve remains closed. With both valves closed the coolant is stagnant and does not circulate in the engine (cylinder block and cylinder head) or through any other cooling system component to significantly decrease the engine warm up time. This reduces emissions and fuel consumption during warm-up.

Phase 2

During an initial start-up with an ambient temperature 60-75°F (16-24°C) or cooler (calibratable) the heater shut-off valve remains open. This allows engine coolant to circulate through the heater core providing cabin heat to the customer. When the heater shut-off valve is open, the coolant circulates through the engine (cylinder block and cylinder head), heater core, engine oil cooler, transmission oil cooler, turbo, and degas bottle. Coolant is also routed into the thermostat housing which initiates the warm-up phase of the thermostat.

Phase 3

The engine coolant bypass valve is energized and opens when engine coolant reaches (158°F) 70°C and the engine load is greater than 70% or engine speed is greater than 4, 000rpm. When the engine coolant bypass valve opens coolant is routed through a coolant between the engine block output and thermostat housing. The opening of this coolant circuit increases the coolant flow rate through the engine block which reduces cooling system pressure and temperature fluctuations in the engine block.

Phase 4

At about (194°F) 90°C, the thermostat opens and the coolant is routed through the radiator. However, the thermostat opening temperature is partially variable via the engine coolant bypass valve. The temperature around the thermostat and its expansion element is the total of the coolant temperatures entering the thermostat housing. Targeted actuation of the engine coolant bypass valve allows increased flow of coolant from the engine block to contact the thermostat element and allows an actual coolant temperature of between (194°F) 90°C and (212°F) 100°C to be set. During part throttle driving, fuel consumption depends heavily on coolant temperature. Closing of the engine coolant bypass valve makes it possible to drive with a higher coolant temperature during part throttle conditions.

Possible Sources

1. Coolant hoses or tubes
2. Hose clamps
3. Thermostat O-ring seal or gasket
4. Coolant pump O-ring seal or gasket
5. Thermostat housing
6. Radiator
7. Pressure relief cap
8. Coolant pump leaking from weep hole
9. Heater core
10. Engine gaskets
11. Degas bottle
12. Transmission fluid heater coolant control valve
13. Transmission fluid cooler coolant control valve
14. Transmission fluid cooler - warmer (may leak internally or externally)
15. Cylinder block core plugs
16. Cylinder head core plugs
17. Heater shut-off valve (1.6L GTDI)
18. Engine coolant bypass valve (1.6L GTDI)
19. Block heater (if equipped)

1. Low coolant level
2. External engine coolant leak
3. Airlock in system
4. Pressure relief cap installation
5. Restricted airflow through the A/C condenser/radiator
6. Internal engine coolant leak
7. Coolant condition/concentration
8. Accessory drive components
9. Non-OEM engine enhancement components
10. Electric cooling fan
11. Engine temperature gauge
12. CHT sensor
13. Heater core
14. Coolant pump
15. Coolant flow restriction
16. Engine coolant bypass valve (1.6L GTDI)
17. Heater shut-off valve (1.6L GTDI)

1. Low coolant level
2. Thermostat
3. Engine temperature gauge
4. Engine coolant bypass valve (1.6L GTDI)
5. ECT sensor (1.6L GTDI)
6. Cylinder Head Temperature (CHT) sensor

1. Fuse(s)
2. Wiring, terminals or connectors
3. Engine coolant bypass valve
4. PCM

1. Fuse(s)
2. Wiring, terminals or connectors
3. Heater shut-off valve
4. PCM

Thermostat

A new thermostat should be installed only after the following tests and checks have been carried out

1. Pinpoint Test B or C
2. Thermostat Visual Inspection

Filling and Bleeding with a Vacuum Cooling System Filler

Note. The cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of the coolant. Failure to follow these instructions may damage the engine or cooling system.

Note. Engine coolant provides boil protection, corrosion protection, freeze protection, and cooling efficiency to the engine and cooling components. In order to obtain these protections, maintain the engine coolant at the correct concentration and fluid level in the degas bottle. To maintain the integrity of the coolant and the cooling system: Add Motorcraft® Orange Antifreeze/Coolant or equivalent. Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the coolant's corrosion protection. Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft® Orange Antifreeze/Coolant since a Ford-approved recycling process is not yet available. When adding or topping off the engine coolant: Measure the coolant concentration in the vehicle using Coolant/Battery Refractometer 300-ROB75240 or equivalent. Determine the concentration desired based on the vehicle duty cycle of extreme hot or cold operating conditions. Add, top off or adjust the coolant as follows: for concentrations measured 48/52 to 50/50 (equates to a freeze point between -34°C (-30°F) and -37°C (-34°F)), use Motorcraft® Orange Antifreeze/Coolant Prediluted to maintain a coolant concentration in this same range (freeze protection down to -37°C (-34°F)). for all other concentrations, use Motorcraft® Orange Antifreeze/Coolant Concentrated and/or distilled water to get to the desired concentration. When refilling the engine coolant after a flush procedure, use a mixture of Motorcraft® Orange Antifreeze/Coolant Concentrated and distilled water to get to the desired concentration.

Scheme 47

1. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill and bleed the cooling system. Recommended coolant concentration is 48/52 to 50/50 (freeze protection -34°C (-30°F) and -37°C (-34°F)) engine coolant to distilled water. For extremely cold climates (less than -37°C (-34°F): It may be necessary to increase the coolant concentration above 50%. NEVER increase the coolant concentration above 60%. Maximum coolant concentration is 60/40 for cold weather areas. A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F). Engine coolant concentration above 60% decreases the overheat protection characteristics of the engine coolant and may damage the engine. For extremely hot climates: It is still necessary to maintain the coolant concentration above 40%. NEVER decrease the coolant concentration below 40%. Minimum coolant concentration is 40/60 for warm weather areas. A coolant concentration of 40% provides freeze point protection down to -34°C (-30°F). Engine coolant concentration below 40% decreases the corrosion and freeze protection characteristics of the engine coolant and may damage the engine. Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 (freeze protection -34°C (-30°F) and -37°C (-34°F)) mixture of engine coolant and distilled water for optimum cooling system and engine protection.
2. When the fill and bleed of the cooling system is complete, perform the COOLING SYSTEM PURGE AND FILL procedure. This procedure is to rid the cooling system of any air bubbles. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-569571-S38562264622013072700000) .

Filling and Bleeding without a Vacuum Cooling System Filler

Note. The cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of the coolant. Failure to follow these instructions may damage the engine or cooling system.

Note. Engine coolant provides boil protection, corrosion protection, freeze protection, and cooling efficiency to the engine and cooling components. In order to obtain these protections, maintain the engine coolant at the correct concentration and fluid level in the degas bottle. To maintain the integrity of the coolant and the cooling system: Add Motorcraft® Orange Antifreeze/Coolant or equivalent. Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the coolant's corrosion protection. Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing. Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft® Orange Antifreeze/Coolant since a Ford-approved recycling process is not yet available. When adding or topping off the engine coolant: Measure the coolant concentration in the vehicle using Coolant/Battery Refractometer 300-ROB75240 or equivalent. Determine the concentration desired based on the vehicle duty cycle of extreme hot or cold operating conditions. Add, top off or adjust the coolant as follows: for concentrations measured 48/52 to 50/50 (equates to a freeze point between -34°C (-30°F) and -37°C (-34°F)), use Motorcraft® Orange Antifreeze/Coolant Prediluted to maintain a coolant concentration in this same range (freeze protection down to -37°C (-34°F)). for all other concentrations, use Motorcraft® Orange Antifreeze/Coolant Concentrated and/or distilled water to get to the desired concentration. When refilling the engine coolant after a flush procedure, use a mixture of Motorcraft® Orange Antifreeze/Coolant Concentrated and distilled water to get to the desired concentration.

1. Fill the degas bottle to the MAX FILL line. Recommended coolant concentration is 48/52 to 50/50 (freeze protection -34°C (-30°F) and -37°C (-34°F)) engine coolant to distilled water. For extremely cold climates (less than -37°C (-34°F): It may be necessary to increase the coolant concentration above 50%. NEVER increase the coolant concentration above 60%. Maximum coolant concentration is 60/40 for cold weather areas. A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F). Engine coolant concentration above 60% decreases the overheat protection characteristics of the engine coolant and may damage the engine. For extremely hot climates: It is still necessary to maintain the coolant concentration above 40%. NEVER decrease the coolant concentration below 40%. Minimum coolant concentration is 40/60 for warm weather areas. A coolant concentration of 40% provides freeze point protection down to -34°C (-30°F). Engine coolant concentration below 40% decreases the corrosion and freeze protection characteristics of the engine coolant and may damage the engine. Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 (freeze protection -34°C (-30°F) and -37°C (-34°F)) mixture of engine coolant and distilled water for optimum cooling system and engine protection.
2. Install the degas bottle cap until it contacts the hard stop.
3. NOTE: If the engine overheats or the fluid level drops below the minimum fill line, shut off the engine and add fluid to the degas bottle maximum fill line once the engine cools. Failure to follow these instructions may result in damage to the engine. Start the engine and let it idle for 30 minutes or until the engine reaches normal operating temperature.
4. Allow the engine to cool and repeat Step 2 if necessary.
5. Start the engine and turn the heater to the MAX position.
6. NOTE: If the engine overheats or the fluid level drops below the minimum fill line, shut off the engine and add fluid to the degas bottle maximum fill line once the engine cools. Failure to follow these instructions may result in damage to the engine. Run the engine at 2, 500 rpm for 10 minutes.
7. Allow the engine to cool and repeat Step 2 if necessary.
8. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Check the engine coolant level in the degas bottle and fill as necessary.
9. When the fill and bleed of the cooling system is complete, perform the COOLING SYSTEM PURGE AND FILL procedure. This procedure is to rid the cooling system of any air bubbles. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-569571-S38562264622013072700000) .

Cooling System Purge and Fill

1. Release the system pressure by loosening the pressure relief cap.
2. Fill the degas bottle to the MAX FILL line.
3. Install the degas bottle cap until it contacts the hard stop.
4. Turn the climate control system off.
5. Start the engine and increase the engine speed to 3, 500 rpm and hold for 30 seconds.
6. Turn the engine off for and wait for 1 minute to purge any large air pockets from the cooling system.
7. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Check the engine coolant level in degas bottle and if necessary fill to 25 mm (0.984 in) above the MAX FILL line on the degas bottle if the engine is warm or to the top of the MAX FILL line if the engine is cold.
8. Start the engine and let it idle until the engine reaches normal operating temperature and the thermostat is fully open. A fully open thermostat is verified by the cooling fan cycling on at least once.
9. Increase the engine speed to 3, 500 rpm and hold for 30 seconds.
10. Allow the engine to idle for 30 seconds.
11. Turn the engine off for 1 minute.
12. Repeat steps 9 through 12 a total of 10 times to remove any remaining air trapped in the system.
13. WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury. Check the engine coolant level in degas bottle and if necessary fill to 25 mm (0.984 in) above the MAX FILL line on the degas bottle if the engine is warm or to the top of the MAX FILL Line if the engine is cold.
14. Install the degas bottle cap until it contacts the hard stop.

Thermostat Housing - 1.6L GTDI

Thermostat Housing - 2.0L GTDI

Thermostat Housing - 2.5L

Bypass Tube - 2.5L

Coolant Pump - 1.6L GTDI

SPECIAL TOOLS Pin, Crankshaft Top Dead Center (TDC) 303-748 Tool, Timing Belt Holding 303-1556

Scheme 48

Coolant Pump - 2.0L GTDI

MATERIAL SPECIFICATIONS

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Drain the cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-569571-S38562264622013072700000) .
2. Turn the component CCW through 1 complete turn.
3. NOTE: Make sure the accessory drive belt is positioned so coolant can not contaminate the belt.
4. NOTE: Cover the A/C belt to prevent coolant contamination of the belt. Completely cover the A/C belt with waterproof plastic.
5. Discard the specified component. Follow local disposal regulations.

Scheme 53

Scheme 54

1. Apply the specified lubricant to the specified component. Material: Motorcraft Orange Antifreeze/Coolant. Tighten to 10 Nm (89 lb-in).
2. Visually inspect.
3. Tighten to 20 Nm (177 lb-in).
4. Fill and bleed the cooling system. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-569571-S38562264622013072700000) .

Coolant Pump - 2.5L

MATERIAL SPECIFICATIONS

Cooling Fan Motor and Shroud

Cooling Module

Degas Bottle

Engine Coolant Bypass Valve