Engine Cooling: Other Ford Fusion I facelift

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Fail Safe Cooling (2.3L and 3.5L only)

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

Note. After the cylinder deactivation operation has begun, the engine will not revert to operating on all cylinders, even if the temperature should fall, until the ignition is switched OFF and then ON again.

Note. The Malfunction Indicator Lamp (MIL) can only be extinguished by using a scan tool after the fault has been rectified and the DTC cleared.

The vehicle has a strategy built into the PCM that will control the engine if it 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 be stopped. At this point, DTC P1285 is set in the PCM and 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 cylinders and restricting the RPM to below 3,000 RPM. Simultaneously, the MIL will be illuminated. This indicates that long-term engine damage can occur and vehicle emissions will be affected. At this point, DTC 1299 is set in the PCM and can be retrieved using a scan tool.

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

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.

Coolant Flow Diagram

Note. Black arrows indicate hot, white arrows indicate cold.

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Note. Black arrows indicate hot, white arrows indicate cold.

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Note. Black arrows indicate hot, white arrows indicate cold.

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Special Tools Illustration Tool Name Tool Number 73III Automotive Meter 105-R0057 or equivalent Battery/Antifreeze Tester 014-R1060 or equivalent Pressure Test Kit 014-R1072 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware or equivalent scan tool

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Cap

1. Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap if necessary.
2. Fit the pressure relief cap to the Radiator/Heater Core Pressure Tester Kit using the correct adapter.
3. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release the pressure and repeat the test. Install a new pressure relief cap if the pressure is not within specification. Refer to «SPECIFICATIONS»(ref-291897-S11066163982008073000000) .

Thermostat

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

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

Filling and Bleeding with RADKITPLUS

1. Install the RADKITPLUS and follow the manufacturer's instructions to fill and bleed the cooling system.

Filling and Bleeding without RADKITPLUS

Note. Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle. When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water. To maintain the integrity of the coolant and the cooling system: Vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant. Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types. Do not add/mix orange-colored Motorcraft Specialty Orange Engine Coolant or equivalent meeting Ford specification WSS-M97B44-D or green-colored Premium 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 Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available. Used engine coolant should be disposed of in an appropriate manner. Follow the community's regulations and standards for recycling and disposing of automotive fluids.

Note. Stop-leak style pellets/products must not be used as an additive in this engine cooling system. The addition of stop-leak style pellets/products can clog or damage the cooling system, resulting in degraded cooling system performance and/or failure.

2.3L engine

1. Open the degas bottle cap and the bleed valve on the back of the engine water outlet.
2. Open the degas bottle cap and the bleed valve on the upper radiator hose.
3. Fill the degas bottle to the MAX fill line.
4. Close the degas bottle cap and the bleed valve.
5. Start the engine and let it idle for 10 minutes (3.0L), 30 minutes (2.3L) or until the engine reaches normal operating temperature.
6. Allow the engine to cool and repeat Step 3 if necessary.
7. Start the engine and turn the heater to the MAX position.
8. Run the engine at 2,500 RPM for 10 minutes.
9. Repeat Step 8 if necessary.
10. Check the engine coolant level in degas bottle and fill as necessary.
11. Open the degas bottle cap and fill the degas bottle to the MAX fill line.
12. Close the degas bottle cap.
13. Start the engine and let idle for 10 minutes or until the engine reaches normal operating temperature.
14. Repeat Step 13 if necessary.
15. Start the engine and turn the heater to the MAX position.
16. Idle engine until the fan turns on, indicating the thermostat is fully open. Increase engine speed to 2,500 RPM for 30 seconds. Idle engine for 2 minutes. Repeat Steps 1 and 2 five times.
17. Repeat Step 16 if necessary.
18. Check the engine coolant level in the degas bottle and fill as necessary.

Thermostat Housing - 2.3L

Note. The thermostat and thermostat housing are serviced as an assembly.

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Thermostat Housing - 3.5L

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Bypass Tube - 3.0L

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Coolant Pump - 2.3L

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Coolant Pump - 3.0L

Special Tools Illustration Tool Name Tool Number Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Power Steering Pump Pulley (Nut only) 211-185 (T91P-3A733-A) Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-A455 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455

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Coolant Pump - 3.5L

Special Tools Illustration Tool Name Tool Number Camshaft Holding Tool 303-1248

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