Engine Cooling - 2.0L Duratec-He: Diagnosis Ford Focus III

DTC Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to DIAGNOSTIC METHODS for information about these practices.

PCM DTC CHART

Inspection and Verification

Note. The engine cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Always fill the cooling system with the manufacturer's specified coolant. Chemically flush the cooling system if a non-specified coolant has been used. Refer to Cooling System Flushing . Failure to follow these instructions may damage the engine or cooling system.

Note. During normal vehicle operation, Motorcraft® Orange Antifreeze/Coolant may change color from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change does not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the system to be flushed, or the engine coolant to be replaced.

1. Verify the customer concern.
2. Visually check the engine coolant level at the degas bottle when the system is cold.
3. Make sure the pressure relief cap is installed correctly.
4. Record any cooling system Diagnostic Trouble Codes (DTCs) retrieved. Refer to the «PCM DTC CHART»(ref-515984-S19125061442012120400000) for DTC descriptions.
5. If the system coolant is filled correctly and no Diagnostic Trouble Codes (DTCs) associated with fail-safe cooling are retrieved, verify the customer concern by operating the engine to duplicate the condition.
6. Visually inspect for obvious signs of any mechanical or electrical damage. VISUAL INSPECTION CHART Mechanical Electrical Leaks or weeps at: Hoses Tubes Hose clamps Engine gaskets (may leak internally or externally) Thermostat housing Radiator Pressure relief cap Coolant pump Engine oil cooler (may leak internally or externally) (if equipped) Heater core (wet floor or coolant odor in vehicle) Degas bottle Cylinder block core plugs Cylinder head core plugs Block heater (if equipped) Cracked or damaged: Hoses Tubes Hose clamps Thermostat housing Radiator Pressure relief cap Cooling fan Coolant pump Engine oil cooler (if equipped) Degas bottle Cylinder block core plugs Cylinder head core plugs Block heater (if equipped) Restricted airflow through the A/C condenser/radiator Excessive white or light gray exhaust smoke (may have burnt coolant odor) Coolant in engine oil Engine oil in coolant Inoperative or damaged: Electric cooling fan Wiring, connectors, relays or modules CHT sensor VSS
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary.
8. Inspect the coolant condition. Inspect the coolant color. If Motorcraft® Orange Antifreeze/Coolant has a clear or pale color, this indicates higher water content than required. Test the engine coolant freezing point range with the Coolant/Battery Refractometer. Maintain the coolant concentration within 48% to 50%, which equates to a freeze point between -31° C and -37°C (-30°F and -34°F). If the vehicle is driven in cold climates less than -37° C (-34° F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 48/52 to 50/50 (freeze protection -31° C to -37°C [-30° F to -34°F]) engine coolant to distilled water. Discoloration may indicate that incorrect coolant may have been added to the system. Use of incorrect (green or yellow in color) coolant degrades the corrosion protection of Motorcraft® Orange Antifreeze/Coolant. Addition of Motorcraft® Specialty Green Engine Coolant may cause the color to appear to be a murky green-brown color. The addition of Motorcraft® Premium Gold Engine Coolant with Bittering Agent, however, may not change the color or appearance of Motorcraft® Orange Antifreeze/Coolant. Detection of contamination with Motorcraft® Premium Gold Engine Coolant with Bittering Agent is determined by the presence of nitrite. If contamination with Motorcraft® Premium Gold Engine Coolant with Bittering Agent is suspected, test the coolant with the 3-Way HD Antifreeze Coolant Test Kit. Follow the nitrite testing directions in the kit to determine if nitrite is present in the system. If nitrite is present, flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. REFER to: «Cooling System Flushing»(ref-515984-S10903742292012120400000) . A darker orange with the presence of debris could indicate a commercially available stop leak may have been used and could result in loss of coolant flow to critical parts of the engine. If sediment is present, flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. REFER to: «Cooling System Flushing»(ref-515984-S10903742292012120400000) . A light or reddish brown color indicates that rust may be present in the cooling system. Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. REFER to: «Cooling System Flushing»(ref-515984-S10903742292012120400000) . An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For engine diagnosis, REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. REFER to: «Cooling System Flushing»(ref-515984-S10903742292012120400000) . A milky brown color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to «Component Tests»(ref-515984-S08281043282012120400000) . If engine oil is suspected, the cause of the leak may be internal to the engine. For engine diagnosis, REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. REFER to: «Cooling System Flushing»(ref-515984-S10903742292012120400000) . If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the Coolant/Battery Refractometer. Maintain the coolant concentration within 48% to 50%, which equates to a freeze point between -31° C and -37°C (-30° F and -34°F). If the vehicle is driven in cold climates less than -36.7 C (-34 F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 48% to 50% (freeze protection -31° C to -37°C [-30° F to -34°F]) engine coolant to distilled water. Maximum coolant concentration is 60/40 for cold weather areas. Minimum coolant concentration is 40/60 for warm weather areas. Adjust coolant range and level if necessary: If coolant is low, add Motorcraft® Orange Antifreeze/Coolant Prediluted. If the engine coolant tests too weak, remove some of the engine coolant and add Motorcraft® Orange Antifreeze/Coolant Concentrated until the readings are within acceptable levels. If the engine coolant tests strong, remove some of the engine coolant and add distilled water until the readings are within acceptable levels.
9. If an obvious cause for an observed or reported concern is found, correct the cause and test the system for normal operation before proceeding to the next step.
10. If the cause is not visually evident, connect the scan tool to the DLC.
11. If the scan tool does not communicate with the VCM : Check the VCM connection to the vehicle. Check the scan tool connection to the VCM. No Power To The Scan Tool, to diagnose no power to the scan tool REFER to: «COMMUNICATIONS NETWORK»(ref-515972-S05756060702012120400000) .
12. If the scan tool does not communicate with the vehicle: Verify the ignition key is in the ON position. Verify the scan tool operation with a known good vehicle. To diagnose no response from the PCM REFER to: «COMMUNICATIONS NETWORK»(ref-515972-S05756060702012120400000) .
13. Carry out the network test. If the scan tool responds with no communication for one or more modules, REFER to: «COMMUNICATIONS NETWORK»(ref-515972-S05756060702012120400000) . If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes (CMDTCs).
14. Clear the continuous Diagnostic Trouble Codes (DTCs) and carry out the self-test diagnostics PCM
15. If the Diagnostic Trouble Codes (DTCs) recovered are related to the concern, go to the PCM DTC Chart. For all other PCM Diagnostic Trouble Codes (DTCs), REFER to: «ELECTRONIC ENGINE CONTROLS»(ref-515938-S29497606342012120400000) .
16. If no Diagnostic Trouble Codes (DTCs) related to the concern are retrieved, GO to «Symptom Chart»(ref-515984-S05802118222012120400000) .

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.

PINPOINT TEST A: PINPOINT TEST

1. A1 Carry out inspection and verification. Carry out «Inspection and Verification»(ref-515984-S21971195442012120400000) . Are any concerns present? Yes: REPAIR as needed. No: GO to A2
2. A2 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE ENGINE COOLING SYSTEM NOTE: Allow the engine to cool before checking the engine coolant level. Ignition OFF Visually inspect the engine coolant level at the degas bottle and adjust as necessary. Pressure test the engine cooling system. Refer to «Cooling System Pressure Test»(ref-515984-S22603259762012120400000) . Does the engine cooling system leak externally? Yes: REPAIR or INSTALL new components. No: GO to A3
3. A3 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle for signs of engine oil. Is engine oil evident in the coolant? Yes: REFER to: «ENGINE»(ref-515979-S33033004782012120400000) . No: GO to A4
4. A4 CHECK THE ENGINE OIL FOR COOLANT Remove the oil level indicator from the engine. Is coolant evident in the oil? Yes: REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . No: GO to A5
5. A5 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent. Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases. Are combustion gases present? Yes: REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . No: The cooling system is operational

PINPOINT TEST B: PINPOINT TEST

1. B1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «Inspection and Verification»(ref-515984-S21971195442012120400000) . Are any concerns present? Yes: REPAIR as needed. No: GO to B2
2. B2 CHECK FOR AN AIRFLOW OBSTRUCTION Check the radiator or A/C condenser for an external obstruction such as leaves or cardboard. Is an obstruction present? Yes: REMOVE the obstruction. No: GO to B3
3. B3 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE COOLING SYSTEM Ignition OFF. Visually check the engine coolant level in the degas bottle and adjust as necessary. Pressure test the cooling system. Does the engine cooling system leak externally? Yes: REPAIR or INSTALL new components. No: GO to B4
4. B4 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle for signs of engine oil. Is engine oil evident in the coolant? Yes: REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . No: GO to B5
5. B5 CHECK THE ENGINE OIL FOR COOLANT Remove the oil level indicator from the engine. Is coolant evident in the oil? Yes: REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . No: GO to B6
6. B6 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent. Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases. Are combustion gases present? Yes: REFER to: «ENGINE»(ref-515962-S16937650842012120400000) . No: GO to B7
7. B7 CHECK COOLANT CONDITION Check the coolant for dirt, rust or contamination and check the coolant concentration. Is the coolant condition OK? Yes: GO to B8 No: FLUSH the engine cooling system. REFER to: «Cooling System Flushing»(ref-515984-S10903742292012120400000) .
8. B8 CHECK THE ELECTRIC COOLING FAN OPERATION Start the engine. Place the climate control function selector in the MAX A/C position and the blower motor switch in the HI position. Yes: GO to B9 No: DIAGNOSE the electric cooling fan operation. REFER to the ENGINE CONTROLS - SYMPTOM CHARTS (EXCEPT DIESEL & HYBRID) .
9. B9 CHECK THE COOLANT PUMP OPERATION Start the engine. Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT position. Feel the heater outlet hose. Is the heater outlet hose hot? Yes: GO to B10 No: INSTALL a new coolant pump. REFER to: «Coolant Pump»(ref-515984-S20895661042012120400000) .
10. B10 CHECK THE THERMOSTAT OPERATION Start the engine. Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT position. Feel the lower radiator hose. Is the lower radiator hose hot? Yes: CHECK the temperature gauge operation. REFER to: «INSTRUMENTATION, MESSAGE CENTER AND WARNING CHIMES»(ref-515970-S19743973642012120400000) . No: GO to B11
11. B11 VISUALLY INSPECT THE THERMOSTAT Carry out the «Thermostat Visual Inspection»(ref-515984-S25476786952012120400000) . Is the thermostat damaged? Yes: INSTALL a new thermostat housing. REFER to: «Thermostat Housing»(ref-515984-S03620469072012120400000) . No: INSTALL a new thermostat housing. REFER to: «Thermostat Housing»(ref-515984-S03620469072012120400000) . If the engine still overheats, INSTALL a new radiator. REFER to: «Radiator»(ref-515984-S03776411122012120400000) .

PINPOINT TEST C: PINPOINT TEST

1. C1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «Inspection and Verification»(ref-515984-S21971195442012120400000) . Were any concerns found? Yes: REPAIR as needed. No: GO to C2
2. C2 CHECK FOR DTC P0125 OR P0128 Using a scan tool, perform the PCM self-test. Is DTC P0125 or P0128 present? Yes: GO to C3 No: The cooling system is operational. If an inoperative temperature gauge is suspected, CHECK the temperature gauge operation. REFER to: «INSTRUMENTATION, MESSAGE CENTER AND WARNING CHIMES»(ref-515970-S19743973642012120400000) . If an inoperative climate control system is suspected, CHECK the climate control system operation. For electronic manual temperature control, REFER to: «CLIMATE CONTROL SYSTEM - VEHICLES WITH: ELECTRONIC MANUAL TEMPERATURE CONTROL (EMTC)»(ref-515934-S26894164542012120400000) . For dual automatic temperature control, REFER to: «CLIMATE CONTROL SYSTEM - VEHICLES WITH: DUAL AUTOMATIC TEMPERATURE CONTROL»(ref-515934-S28897929582012120400000) . If any other Diagnostic Trouble Codes (DTCs) are retrieved, REFER to: «ELECTRONIC ENGINE CONTROLS»(ref-515938-S29497606342012120400000) .
3. C3 CHECK THE COOLANT LEVEL NOTE: Allow the engine to cool before checking the degas bottle. Visually check the engine coolant level in the degas bottle Is the engine coolant level within specification? Yes: INSTALL a new thermostat housing. REFER to: «Thermostat Housing»(ref-515984-S03620469072012120400000) . CLEAR Diagnostic Trouble Codes (DTCs). If the DTC returns check for correct CHT sensor operation. No: GO to «Pinpoint Test A»(ref-515984-S31789470472012120400000)

Cooling System Pressure Test

Note. Vehicles have a pressure relief cap on the degas bottle and no radiator cap.

1. Turn the engine OFF.
2. Check the engine coolant and adjust as necessary.
3. Attach the Pressure Tester to the degas bottle nipple and overflow hose. Install a pressure test pump to the quick connect fitting of the test adapter.
4. Slowly press the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained. If the pressure reading exceeds the maximum cap pressure listed in the Specifications table, install a new pressure relief cap.
5. If the system does not hold pressure, remove the pressure relief cap and wash in clean water to dislodge all the foreign material from the gasket. Check the sealing surface in the filler neck of the degas bottle for nicks or cuts. Install the pressure relief cap.
6. Pressurize the engine cooling system as described in Step 4 above. Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.
7. If no leaks are found and the pressure drops. the pressure relief cap may be leaking. Install a new pressure relief cap and retest the system.
8. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. REFER to: «ENGINE»(ref-515979-S33033004782012120400000) . to diagnose the engine.
9. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as necessary.

Thermostat Visual Inspection

1. Remove the thermostat.
2. Examine the thermostat for signs of damage including: Valve not fully seated (light visible through the valve) Foreign material lodged in the main valve Bent or broken frame or flange Bent or broken spring Wax leaking from wax reservoir or a bulge in the reservoir Any other damage or distortion
3. If damage is found during the inspection, remove any foreign material or broken pieces and install a new thermostat.

Radiator Leak Test, Removed From Vehicle

Note. Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators.

Note. Clean the radiator before leak testing to avoid contamination of tank.

1. Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the Specifications table.