Engine Cooling: Diagnosis Ford Freestyle I

Inspection and Verification

Note. Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

1. Verify the customer concern.
2. Visually check the engine coolant level at the degas bottle or coolant expansion tank 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 «POWERTRAIN CONTROL MODULE (PCM) DTC TABLE»(ref-255255-S39642571692007053000000) for DTC descriptions.
5. NOTE: Take note of any coolant odor or steam coming from cooling system components. If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved, verify the customer's concern by operating the engine to duplicate the condition.
6. Inspect to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION TABLE Mechanical Electrical Leaks or weeps at: Hoses Tubes Clamp joints Quick connect couplings (if equipped) Gaskets O-rings Thermostat housing Radiator Pressure relief cap Coolant pump Heater core (wet floor or coolant odor in vehicle) Heater control valve Heated throttle body or heated throttle body adapter (if equipped) Coolant crossover manifold assembly (if equipped) Oil cooler (if equipped) Degas bottle (if equipped) Coolant expansion tank (if equipped) Heated positive crankcase ventilation (PCV) (if equipped) Fuel pressure regulator Clayton bowl (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) Inoperative or damaged: Electric cooling fan (if equipped) Electronically actuated fan clutch Electronically actuated fan clutch controller Wiring, connectors, relays or modules Engine coolant temperature (ECT) sensor (if equipped) Cylinder head temperature (CHT) sensor (if equipped) Intake air temperature (IAT) sensor (if equipped) Mass air flow (MAF) sensor Vehicle speed sensor (VSS) VISUAL INSPECTION TABLE Mechanical Electrical Cracked or damaged: Hoses Tubes Hose clamps Heater control valve (if equipped) Thermostat housing Radiator Pressure relief cap Cooling fan Fan clutch (if equipped) Coolant pump Degas bottle (if equipped) Coolant expansion tank (if equipped) Oil cooler (if equipped) Coolant crossover manifold assembly (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) Restricted airflow through the A/C condenser/radiator Drive belt loose, worn or installed incorrectly Broken or weak drive belt tensioner Excessive white or light gray exhaust smoke (may have burnt coolant odor) Coolant in engine oil Engine oil in coolant Coolant in automatic transmission fluid (if equipped) Automatic transmission fluid (if equipped) in coolant
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test the system for normal operation.
8. Inspect the coolant condition. Inspect the coolant color. If Motorcraft Premium Gold Engine Coolant has a clear or pale yellow color, this indicates higher water content than required. Test the engine coolant freezing point range with the Battery/Anti-Freeze Tester. The freezing point should be in the range -45°C to -23°C (-50°F to -10°F). If the vehicle is driven in cold climates less than -36°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. A pale green color indicates incorrect coolant (green in color) may have been added to the system. Use of incorrect (green in color) coolant degrades the corrosion protection of Motorcraft Premium Gold Engine Coolant. Flush the system and refill with the correct mixture of distilled water and Motorcraft Premium Gold Engine Coolant. NOTE: If Cooling System Stop Leak Pellets are used, darkening of the Motorcraft Premium Gold Engine Coolant from yellow to golden tan will occur. Dark brown could indicate a commercially available stop leak may have been used. Flush the system and refill with the correct mixture of distilled water and Motorcraft Premium Gold Engine Coolant. 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 Premium Gold Engine Coolant. An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For information on engine diagnosis, refer to «ENGINE»(ref-255260-S25501764452007053000000) . A milky brown color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to «COMPONENT TESTS»(ref-255255-S42142664772007053000000) . If engine oil is suspected, the cause of the leak may be internal to the engine. Refer to «ENGINE»(ref-255260-S25501764452007053000000) . A red, orange or light green colored sheen on top of the coolant may indicate that transmission fluid is entering the cooling system. The cause may be a leaky radiator. Pressure test the cooling system. Refer to «COMPONENT TESTS»(ref-255255-S42142664772007053000000) . If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the Battery/Anti-Freeze Tester. The freezing point should be in the range -45°C to -23°C (-50°F to -10°F). If the vehicle is driven in cold climates less than -36°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 50/50 ethylene glycol 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 specified coolant mixture only. If the engine coolant tests too weak, remove some of the engine coolant and add undiluted engine coolant 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 data link connector (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. refer to «PINPOINT TEST O: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC TOOL»(ref-255276-S37308405152007053000000) to diagnose no communication with the scan tool.
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. refer to «PINPOINT TEST F: THE POWERTRAIN CONTROL MODULE (PCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL»(ref-255276-S39502884702007053000000) to diagnose no response from the powertrain control module (PCM).
13. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «PINPOINT TEST O: NO MODULE/NETWORK COMMUNICATION - NO POWER TO THE DIAGNOSTIC TOOL»(ref-255276-S37308405152007053000000) . If the network test passes, retrieve and record continuous memory diagnostic trouble codes (DTCs).
14. Clear the continuous DTCs and carry out the self-test diagnostics for the generic electronic module (GEM).
15. If the DTCs recovered are related to the concern, go to the «POWERTRAIN CONTROL MODULE (PCM) DTC TABLE»(ref-255255-S39642571692007053000000) . For all other DTCs, refer to «DIAGNOSTIC TROUBLE CODE TABLE»(ref-255282-S36837434302007053000000) .
16. If no DTCs related to the concern are retrieved, GO to «SYMPTOM TABLE»(ref-255255-S00442829382007053000000) .

Symptom Table

SYMPTOM TABLE

This pinpoint test is intended to diagnose the following

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. Heater control valve (if equipped)
7. Radiator
8. Transmission fluid cooler (in radiator) (if equipped)
9. Pressure relief cap
10. Coolant pump leaking from weep hole Auxiliary coolant pump (if equipped) Heater core
11. Heated throttle body or heated throttle body adapter (if equipped)
12. Coolant crossover manifold assembly (if equipped)
13. Engine gaskets
14. Oil cooler (if equipped)
15. Degas bottle (if equipped)
16. Coolant expansion tank (if equipped)
17. Heated positive crankcase ventilation (PCV) (if equipped)
18. Fuel pressure regulator coolant bowl (if equipped)
19. Cylinder block core plugs (if equipped)
20. Cylinder head core plugs (if equipped)
21. Block heater (if equipped)
22. Engine coolant temperature (ECT) sensor (if equipped)

PINPOINT TEST A: LOSS OF COOLANT

1. A1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(ref-255255-S23630138762007053000000) procedure. Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to A2 .
2. A2 CHECK THE ENGINE COOLANT LEVEL NOTE: Allow the engine to cool before checking the engine coolant level. Key in OFF position. Visually inspect the engine coolant level at the degas bottle or the coolant expansion tank. Is the engine coolant level within specifications? Yes: GO to A3 . No: ADJUST the engine coolant level as necessary. GO to A3 .
3. A3 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to «COMPONENT TESTS»(ref-255255-S42142664772007053000000) . Does the engine cooling system leak? Yes: REPAIR or INSTALL new components. TEST the system for normal operation. No: If the vehicle is equipped with a coolant expansion tank, GO to A4 . If the vehicle is equipped with a degas bottle, GO to A5 .
4. A4 CHECK THE PRESSURE RELIEF CAP Carry out the pressure relief cap pressure test. Refer to «COMPONENT TEST»(ref-255255-S42142664772007053000000) . Is the pressure relief cap OK? Yes: GO to A5 . No: INSTALL a new pressure relief cap. TEST the system for normal operation.
5. A5 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle or coolant expansion tank for signs of engine oil or transmission fluid. Is engine oil or transmission fluid evident in the coolant? Yes: If engine oil is evident, GO to «ENGINE»(ref-255260-S25501764452007053000000) for engine diagnosis. If transmission fluid is evident, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the «IN-VEHICLE REPAIR»(ref-255262-S24721898912007053000000) for the procedure. TEST the system for normal operation. No: GO to A6 .
6. A6 CHECK THE ENGINE OIL AND TRANSMISSION FLUID FOR COOLANT Remove the oil level indicators from the engine and the transmission. Is coolant evident in the oil or transmission fluid? Yes: If coolant is in the engine oil, GO to «ENGINE»(ref-255260-S25501764452007053000000) . If coolant is in the transmission fluid, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to «IN-VEHICLE REPAIR»(ref-255262-S24721898912007053000000) for the procedure. No: GO to A7 .
7. A7 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use U-View® Combustion Leak Tester part number 560000 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: GO to ENGINE for engine diagnosis.

No: The cooling system is operational.

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 (if equipped)
11. Mechanical cooling fan blade (if equipped)
12. Mechanical cooling fan clutch (if equipped)
13. Engine coolant temperature indicator system (gauge)
14. Engine coolant temperature (ECT) sensor (if equipped)
15. Cylinder head temperature (CHT) sensor (if equipped)
16. Heater core
17. Coolant pump
18. Coolant flow restriction

PINPOINT TEST B: THE ENGINE OVERHEATS

1. B1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(ref-255255-S23630138762007053000000) procedure. Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to B2 .
2. B2 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) NOTE: Refer to the «INTRODUCTION - GASOLINE»(ref-249149) article for correct scan tool hook-up procedure. Check for DTCS P0217, P1285 or P1299. Is DTC P0217, P1285 or P1299 present? Yes: GO to B3 . No: Actual engine overheating has not been verified. CHECK the engine coolant temperature gauge operation. REFER to «PINPOINT TEST C: INCORRECT TEMPERATURE GAUGE INDICATION»(ref-255281-S31040116272007053000000) . If any other DTCs are retrieved, REFER to the «INTRODUCTION - GASOLINE»(ref-249149) article.
3. B3 CHECK FOR AN AIRFLOW OBSTRUCTION Check the radiator or A/C condenser for an obstruction such as leaves or cardboard. Is an obstruction present? Yes: REMOVE the obstruction. TEST the system for normal operation. No: GO to B4 .
4. B4 CHECK THE ENGINE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant level. Key in OFF position. Visually check the engine coolant level in the degas bottle or coolant expansion tank. Is the engine coolant level within specification? Yes: GO to B5 . No: ADJUST the engine coolant level as necessary. GO to B5 .
5. B5 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to «COMPONENT TESTS»(ref-255255-S42142664772007053000000) . Does the engine cooling system leak? Yes: REPAIR or INSTALL new components. TEST the system for normal operation. No: Vehicles equipped with an expansion tank, GO to B6 . Vehicles equipped with a degas bottle, GO to B7 .
6. B6 CHECK THE PRESSURE RELIEF CAP Carry out the pressure relief cap pressure test. Refer to «COMPONENT TEST»(ref-255255-S42142664772007053000000) . Is the pressure relief cap OK? Yes: GO to B7 . No: INSTALL a new pressure relief cap. TEST the system for normal operation.
7. B7 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle or coolant expansion tank for signs of engine oil or transmission fluid. Is engine oil or transmission fluid evident in the coolant? Yes: If engine oil is evident, GO to «ENGINE»(ref-255260-S25501764452007053000000) for engine diagnosis. If transmission fluid is evident, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to «IN-VEHICLE REPAIR»(ref-255262-S24721898912007053000000) for the procedure. TEST the system for normal operation. No: GO to B8 .
8. B8 CHECK THE ENGINE OIL AND TRANSMISSION FLUID FOR COOLANT Remove the oil level indicators from the engine and the transmission. Is coolant evident in the oil or transmission fluid? Yes: If coolant is in the engine oil, GO to «ENGINE»(ref-255260-S25501764452007053000000) . If coolant is in the transmission fluid, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to «IN-VEHICLE REPAIR»(ref-255262-S24721898912007053000000) for the procedure. No: GO to B9 .
9. B9 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use U-View® Combustion Leak Tester part number 560000 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: GO to «ENGINE»(ref-255260-S25501764452007053000000) for engine diagnosis. No: GO to B10 .
10. B10 CHECK COOLANT CONDITION Check the coolant for dirt, rust or contamination and check the coolant concentration. Is the coolant condition OK? Yes: Vehicles equipped with an electric cooling fan, GO to B11 . Vehicles equipped with only a mechanical cooling fan, GO to B12 . No: FLUSH the engine cooling system. REFER to «COOLING SYSTEM FLUSHING»(ref-255255-S21901158912007053000000) . TEST the system for normal operation.
11. B11 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. Did the electric cooling fan operate? Yes: If the vehicle is also equipped with a mechanical cooling fan, GO to B12 . Otherwise, GO to B13 . No: DIAGNOSE the electric cooling fan operation. REFER to «INTRODUCTION - GASOLINE»(ref-249149) article.
12. B12 CHECK THE MECHANICAL COOLING FAN OPERATION Key in OFF position. If the vehicle is equipped with a viscous fan clutch, carry out the «FAN CLUTCH TEST»(ref-255255-S35619083872007053000000) in Component Tests. If the vehicle is equipped with an electronically actuated fan clutch, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. Is the cooling fan operation OK? Yes: GO to B13 . No: INSTALL a new fan clutch. TEST the system for normal operation.
13. B13 CHECK THE COOLANT PUMP OPERATION Start the engine. Allow the engine to run for 10 minutes (hot side thermostat equipped vehicles) or 30 minutes (cold side thermostat equipped vehicles). 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 B14 . No: INSTALL a new coolant pump. TEST the system for normal operation.
14. B14 CHECK THE THERMOSTAT OPERATION Start the engine. Allow the engine to run for 10 minutes (hot side thermostat equipped vehicles) or 30 minutes (cold side thermostat equipped vehicles). Feel the upper radiator hose (hot side thermostat equipped vehicles) or the lower radiator hose (cold side thermostat equipped vehicles). Is the upper (hot side thermostat equipped vehicles) or lower (cold side equipped vehicles) radiator hose hot? Yes: CHECK the engine coolant temperature gauge operation. REFER to «PINPOINT TEST C: INCORRECT TEMPERATURE GAUGE INDICATION»(ref-255281-S31040116272007053000000) . No: GO to B15 .
15. B15 VISUALLY INSPECT THE THERMOSTAT Carry out the «THERMOSTAT VISUAL INSPECTION»(ref-255255-S38280152052007053000000) in Component Tests. Is the thermostat damaged?

Yes: INSTALL a new thermostat. TEST the system for normal operation.

No: INSTALL a new thermostat. TEST the system for normal operation. If the engine still overheats, INSTALL a new radiator. TEST the system for normal operation.

1. Low coolant level
2. Thermostat
3. Engine coolant temperature (ECT) indicator system (gauge)
4. Engine cooling fan

PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

1. C1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(ref-255255-S23630138762007053000000) procedure. Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to C2 .
2. C2 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) P0125 or P0128 NOTE: Refer to the «INTRODUCTION - GASOLINE»(ref-249149) article for correct scan tool hook-up procedure. Check for DTCs P0125 or P0128. Is DTC P0125 or P0128 present? Yes: If the vehicle is equipped with an electric cooling fan, GO to C3 . If the vehicle is equipped with only a mechanical cooling fan, GO to C4 . No: The cooling system is operational. If an inoperative engine coolant temperature gauge is suspected, CHECK the engine coolant temperature gauge operation. REFER to «PINPOINT TEST C: INCORRECT TEMPERATURE GAUGE INDICATION»(ref-255281-S31040116272007053000000) . If an inoperative climate control system is suspected, CHECK the climate control system operation. REFER to «CLIMATE CONTROL SYSTEM»(ref-255298-S23120340062007053000000) . If any other DTCs are retrieved, REFER to the «INTRODUCTION - GASOLINE»(ref-249149) article.
3. C3 CHECK THE ELECTRIC COOLING FAN OPERATION Allow the engine to cool. Make sure the A/C switch is OFF (if equipped). Start the engine. Check the electric cooling fan. Is the electric cooling fan on all the time? Yes: DIAGNOSE the electric cooling fan operation. REFER to the «INTRODUCTION - GASOLINE»(ref-249149) article. No: If the vehicle is also equipped with a mechanical cooling fan, GO to C4 . Otherwise, GO to C5 .
4. C4 CHECK THE MECHANICAL COOLING FAN OPERATION Carry out the cooling fan clutch component tests. For a mechanical cooling fan clutch, refer to «COMPONENT TESTS»(ref-255255-S42142664772007053000000) . For an electronic cooling fan clutch, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. Is the cooling fan clutch OK? Yes: GO to C5 . No: INSTALL a new cooling fan clutch. TEST the system for normal operation.
5. C5 CHECK THE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant level. Visually check the engine coolant level in the degas bottle or coolant expansion tank. Is the engine coolant level within specification? Yes: INSTALL a new thermostat. TEST the system for normal operation. No: GO to «PINPOINT TEST A»(ref-255255-S42773828382007053000000) to diagnose a coolant leak.

Pressure Test - Degas Bottle Systems

Note. Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

Pressure Test - Coolant Expansion Tank Systems

Note. Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and no radiator cap. Vehicles equipped with a coolant expansion tank system have the pressure relief cap on the radiator.

Thermostat Visual Inspection

Radiator Leak Test, Removed From Vehicle

Note. Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator. Clean the radiator before leak testing to avoid contamination of tank.

1. Leak test the radiator in clean water with 138 kPa (20 psi) air pressure.

Fan Clutch Test

1. Turn the engine OFF and wait until the fan comes to a complete stop.
2. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked. For an electronically actuated fan clutch, refer to the «INTRODUCTION - GASOLINE»(ref-249149) article. For a viscous fan clutch, carry out the following

Fan Clutch Test - Minimum Speed Requirement

1. Use a suitable marker to mark the coolant pump or fan pulley and one of the fan blades.
2. Make sure the A/C is OFF, if equipped.
3. Start the engine and run it at approximately 2,000 rpm for 5 minutes or until there is a noticeable reduction in fan noise to allow the fan clutch to go into disengaged mode.
4. Aim a laser photo tachometer at the coolant pump or fan pulley. Run the engine to achieve 3,000 rpm at the coolant pump or fan pulley.
5. With the coolant pump or fan pulley at 3,000 rpm, aim the laser photo tachometer at the fan blade. Monitor and record fan speed.
6. The fan blade speed must be less than the specified rpm at 3,000 rpm coolant pump or fan pulley rpm. Refer to «GENERAL SPECIFICATIONS»(ref-255255-S05348257092007053000000) table for correct fan speed.
7. Turn the engine off.
8. If the fan blade speed was greater than specified, install a new fan clutch.

Fan Clutch Test - Maximum Speed Requirement