Engine Cooling System: Other Ford Focus I

Antifreeze

ANTIFREEZE SPECIFICATIONS

Engine Coolant

Engine coolant concentration should be checked through the neck of the expansion tank with a hydrometer. The acceptable range of specific gravity (sg) of correctly balanced fluids is between 11.10 and 11.20 lbs/gal, which represents an engine coolant concentration between 40% and 55%. If the concentration falls below 40% there is insufficient low temperature protection and the corrosion resistance will be inadequate. In such cases the concentration must be brought back to specification.

The engine coolant should not be mixed with other coolant types. For cooling system top up, only use coolant which meets specification. For additional information, refer to SPECIFICATIONS .

Changing Coolant

Note. Providing the coolant has not been contaminated with other fluids or foreign matter, the robust corrosion resistance properties of this coolant means that it can be re - used after changing an aluminum cooling system component, although the concentration should always be checked and maintained within specification.

This engine coolant should be changed after a period of 10 years or 150 000 miles, whichever occurs sooner. Refill with engine coolant mixed to the correct proportions.

Fail - Safe Cooling (Zetec-E only)

The vehicle has a strategy built into the powertrain control module (PCM) that will control the engine if the engine starts to overheat.

Stage 1 of the strategy will commence if the engine starts to overheat. The Cylinder Head Temperature (CHT) sensor transmits a signal to the PCM which then moves the temperature gauge pointer into the red zone.

If the engine is not switched off and the temperature continues to rise, the Powertrain Check Lamp is illuminated. This indicates to the driver that the engine is approaching critical limits and should stop. At this point DTC p1285 is set in the PCM which can be retrieved using a scan tool.

Stage 2 of the strategy will commence if the lamp and temperature gauge are ignored by the driver. The PCM will start to control the engine by cutting out two cylinders and restricting the RPM to below 3000 RPM. Simultaneously the Malfunction Indicator Lamp (MIL) will be illuminated. This indicates that long term engine damage may occur and vehicle emissions will be affected. At this point DTC p1299 is set in the PCM which can be retrieved using a scan tool.

Air is drawn into the deactivated cylinders which helps to control the temperature of the engine internal components. The deactivated cylinders are alternated to allow even cooling of all the cylinders.

Note. If the driver is using a high percentage of throttle travel (for example, an overtaking maneuver) when the PCM starts engine deactivation (stage 2), the deactivation will be delayed for 10 seconds.

Note. After 2 - cylinder operation has begun, the engine will not revert to 4 - cylinder operation, even if the temperature should fall, until the ignition is switched off and then on again.

Note. The MIL can only be extinguished by using a diagnostic tool after the fault has been rectified and the DTC cleared.

Stage 3 of the strategy will commence if the engine temperature still continues to rise. This will result in the engine being totally disabled before major engine damage or seizure occurs. The Powertrain Check Lamp will begin to flash, indicating to the driver that the engine will be switched off after 30 seconds. This allows the driver time to choose a suitable parking place.

Scheme 71

General Equipment

GENERAL EQUIPMENT CHART

Thermostat, Electrical

Note. This procedure is most accurate if carried out indoors at less than 37.8°C (100°F) ambient air. This test may be carried out with or without the hood open and with the engine warm or cold.

1. Check the coolant level in the radiator and the coolant expansion tank. Fill as required.
2. With the engine OFF, disconnect the cylinder head temperature (CHT) sensor electrical connector and attach Service Coolant Temperature Monitor Harness as a jumper between the PCM and the CHT. Attach a digital multimeter to the thermostat monitor harness. Voltage values (0 to 5 V) may now be monitored while the sensor retains its connection to the harness. NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause incorrect diagnosis.
3. Place transmission in Park (P) or Neutral (N).
4. Start the engine and allow to idle throughout this test. Allow the engine to run for 2 minutes, then record the CHT voltage. Record the CHT voltage every 60 seconds. When the CHT voltage trend changes direction or only changes slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart listed below. NOTE: The CHT sensor has a temperature to voltage overlap zone, within this zone it is possible to have either a 'Cold End' or 'Hot End' voltage at the same temperature. For further information, REFER to «CYLINDER HEAD TEMPERATURE SENSOR»(ref-138346-S35011944052002040800000) . COOLANT TEMPERATURE CHART Coolant Temperature °C (°F) CHT (volts) 20 (68) 3.09 40 (104) 2.15 70 (158) 1.04 80 (176) 0.79 or 3.99 90 (194) 0.61 or 3.71 95 (203) 0.53 or 3.56 100 (212) 0.46 or 3.41 110 (230) 3.07
5. If the thermostat opening voltage is greater than 0.79 volts and less than 80°C (176°F), INSTALL a new thermostat.
6. If the thermostat opening voltage is less than 0.79 volts and greater than 80°C (176°F), the thermostat is OK and should not be changed. Refer to the «SYMPTOM CHART»(ref-204922-S03851062892005111500000) for further instructions.

Scheme 72

Scheme 73

Scheme 74

1. Connect the WDS to the data link connector (DLC).
2. Using the WDS 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 The IAT sensor output is useful if the engine being tested is cold or after an over-night cold soak. The ECT sensor or CHT sensor and the IAT sensor should either indicate the same value or be within 1 to 2 degrees Celsius of each other. The ECT sensor output is important to display as it indicates the engine warm-up and opening temperature for the thermostat. It will initially indicate a slightly higher reading just before the thermostat opens and then drops back before settling to a near flat line output (Scheme 72) CAUTION: If the ECT sensor output reaches the 120°C default line under normal cooling system pressure, internal damage may be caused to the engine and a diagnostic trouble code (DTC) will be set in the PCM. The test should be stopped and the cause located and corrected. If the cooling system does not pressurize, the coolant will boil at 100°C which may also damage the engine. CARRY OUT the «COOLANT EXPANSION TANK CAP PRESSURE TEST»(ref-204922-S28469493852005111500000). If the WDS only allows the ECT sensor to be displayed in volts, refer to the following table for corresponding Celsius values: ECT SENSOR DISPLAYED VOLTS REFERENCE Volts °Celsius 1.33 60 1.02 70 0.78 80 0.60 90 0.46 100 0.35 110 0.27 120 The CHT sensor output is useful to examine the cylinder head temperature rise during the warm-up cycle and later during the normal light throttle cruise test. This sensor output may vary between vehicles with manual transmission and vehicles with automatic transmission and should be used for reference only. The LOAD display is used for reference as it is necessary to maintain a stable load line during the test. It is necessary to carry out the test under normal light throttle cruise driving conditions and average loads, typically 40% to 70% of the load value. The VSS output is used for reference but can help to identify misfires and sensors which fail during the warm-up cycle. The RPM display indicates the engine speed and can be compared with the DSRPM. The DSRPM is the desired or calculated idle speed which the PCM commands the engine to reach. If the thermostat opens too early (before the correct opening temperature has been reached), the engine will not reach this value. When using the WDS in data logger mode, the signals recorded should remain within the DEFAULT values set by the WDS.
3. Carry out a road test.
4. Drive the vehicle at a constant throttle opening and set speed until the ECT value settles into a shallow rise and fall signal, close to a straight line. This indicates that the thermostat is functioning correctly. NOTE: Some thermostats indicate the temperature(s) in Celsius and Fahrenheit. The graphic below shows the location and an example of the opening temperature (88°C) and fully open temperature (102°C) of a thermostat. The graphic below shows an alternative method used to show the opening temperature (88°C) and fully open temperature (112°C) of a thermostat. NOTE: Generally, most thermostats maintain a coolant temperature between 88°C (190°F) and 92°C (198°F) although dual stage electric thermostats may increase the coolant temperature up to 100°C (212°F) under light engine load conditions. The engine should start cleanly and the ECT value will rise quite quickly with smooth progression. If the ECT signal appears unstable or erratic, the ECT sensor, electrical connector and wiring harness to the PCM need to be visually inspected for damage, chafing or water ingress. The temperature should rise to approximately 90°C for a thermostat that has an 88°C value. The signal value will then fall as cooler coolant enters the engine. If the ECT value fails to maintain a constant value and falls back to lower figures, typically between 60°C (140°F) and 70°C (150°F), the thermostat and its sealing function within the thermostat housing must be checked.
5. INSTALL a new thermostat if it does not operate as specified: Vehicles with 2.0L Zetec-E engine. REFER to «THERMOSTAT - 2.0L Zetec-E (Zetec)»(ref-204922-S10511673892005111500000). Vehicles with 2.0L SPI engine. REFER to «THERMOSTAT - 2.0L SPI»(ref-204922-S24886869562005111500000). Vehicles with 2.0L Duratec ST engine. REFER to «THERMOSTAT HOUSING - 2.0L Duratec-ST (Zetec)»(ref-204922-S15844669802005111500000).
6. Carry out another road test from step 1 using the same criteria to confirm that the concern has been rectified.
7. Using the WDS, clear the PCM keep alive memory (KAM) or electrically erasable programmable read only memory (EEPROM) so that new drive values can be learnt.

Scheme 75

Scheme 76

Scheme 77

1. Release the cooling system pressure by slowly turning the coolant expansion tank cap a quarter of a turn.
2. Remove the coolant expansion tank cap when all the pressure has been released.
3. Raise and support the vehicle. .
4. Remove the engine undershield (if equipped).
5. Open the radiator drain valve to drain the coolant.
6. Close the drain valve when all the coolant has been drained from the cooling system.
7. Install the engine undershield (if equipped).
8. Lower the vehicle.

Filling and bleeding using Radkitplus

1. Install the special tool.
2. Using the special tool, follow the manufacturer's instructions to fill and bleed the cooling system.

Filling and bleeding without using Radkitplus

Vehicles with 2.0L SPI or 2.0L Zetec-E (Zetec) engine

Cooling System Backflushing

1. Disconnect the heater outlet hose from the engine intake connector and install a garden hose (from a tap), with a male adapter into the end of the heater outlet hose. Secure with a hose clamp.
2. Connect a garden hose to the engine intake connector and secure with a hose clamp. Allow the open end to drain into a suitable container or drain.
3. Turn the water supply tap ON and OFF several times, so that the surge action will help to dislodge larger, stubborn particles from the heater core tubes. Allow water pressure to flow for approximately five minutes.
4. Remove the garden hose with the male adapter from the heater outlet hose. Remove the garden hose from the engine intake connector and reconnect the heater outlet hose onto the engine intake connector.
5. Fill the cooling system as described, using a 50/50 mixture of Ford cooling system fluid and water. For additional information, refer to «SPECIFICATIONS»(ref-204922-S32622496032005111500000) .
6. Test the system for correct heater operation within the engine cooling system conditions.

Scheme 78

Scheme 79

Scheme 80

Scheme 81

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(ref-204922-S37308348142005111500000) .
2. Disconnect the coolant hoses.
3. Remove the thermostat cover bolts.
4. Remove the thermostat.
5. Remove and discard the rubber seal.