Engine Cooling System - 2.0L: Diagnosis Ford Kuga II

DTC Chart

Refer to: ENGINE COOLING SYSTEM HEALTH AND SAFETY PRECAUTIONS .

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

Refer to: DIAGNOSTIC METHODS .

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. 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-658854-S22881784982014092900000) 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 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 DESCRIPTION Mechanical Electrical Leaks or weeps at: Hoses Tubes Clamp joints Gaskets O-rings Thermostat housing Radiator Pressure relief cap Coolant pump Heater core (wet floor or coolant odor in vehicle) Degas bottle Transmission fluid heater coolant control valve Transmission fluid cooler coolant control valve Transmission fluid cooler - warmer (may leak internally or externally) 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 Degas bottle Transmission fluid heater coolant control valve Transmission fluid cooler coolant control valve Transmission fluid cooler - warmer (may leak internally or externally) Cylinder block core plugs Cylinder head core plugs 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 transmission fluid Transmission fluid in coolant Inoperative or damaged: Electric cooling fan Wiring, connectors, relays or modules CHT sensor ECT sensor
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. 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® Gold Antifreeze/Coolant, however, may not change the color or appearance of the orange colored coolant. Detection of contamination with Motorcraft® Gold Antifreeze/Coolant is determined by the presence of nitrite. If contamination with Motorcraft® Gold Antifreeze/Coolant 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 DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) . 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 DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) . 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 DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) . 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-658863-S16845662912014092900000) .. Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) . A milky brown color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to «COMPONENT TESTS»(ref-658854-S19627841402014092900000) . If engine oil is suspected, the cause of the leak may be internal to the engine. For engine diagnosis, Refer to: «ENGINE»(ref-658863-S16845662912014092900000) .. Flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658854-S21377632492014092900000) . 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 -34°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 -34°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 specified coolant mixture only. 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.

Symptom Chart

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

Refer to: DIAGNOSTIC METHODS .

PINPOINT TEST A: PINPOINT TEST

1. A1 CARRY OUT INSPECTION AND VERIFICATION Carry out «INSPECTION AND VERIFICATION»(ref-658854-S32687014002014092900000) . 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-658854-S22253540032014092900000) . 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 engine coolant? Yes : Refer to: «ENGINE»(ref-658863-S16845662912014092900000) .. 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-658863-S16845662912014092900000) .. No : Go to A5
5. A5 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID Check the engine coolant in the degas bottle for signs of transmission fluid. Is transmission fluid evident in the engine coolant? Yes : INSTALL a new transmission cooler - warmer. Refer to: «TRANSMISSION FLUID COOLER - 6-SPEED AUTOMATIC TRANSMISSION - 6F35»(ref-658912-S39708602682014092900000) . REPAIR the transmission as necessary. Refer to: «AUTOMATIC TRANSMISSION - 2.0L ECOBOOST (177KW/240PS) - MI4»(ref-658852-S20169484962014092900000) . TEST the system for normal operation. No : Go to A6
6. A6 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT Remove the transmission oil leveling plug. Check the transmission fluid for engine coolant. Is engine coolant evident in the transmission fluid? Yes : INSTALL a new transmission cooler - warmer. Refer to: «TRANSMISSION FLUID COOLER - 6-SPEED AUTOMATIC TRANSMISSION - 6F35»(ref-658912-S39708602682014092900000) . REPAIR the transmission as necessary. Refer to: «AUTOMATIC TRANSMISSION - 2.0L ECOBOOST (177KW/240PS) - MI4»(ref-658852-S20169484962014092900000) . TEST the system for normal operation. No : Go to A7
7. A7 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-658863-S16845662912014092900000) .. 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-658854-S32687014002014092900000) procedure. Are any concerns present? Yes : REPAIR as needed. No : Go to B2
2. B2 CHECK FOR PCM (POWERTRAIN CONTROL MODULE) DTCS Ignition ON. Using a scan tool, perform PCM self-test. Is DTC P0217 and/or P1299 present? Yes : Go to B3 No : Actual engine overheating has not been verified. CHECK the engine coolant temperature gauge operation. Refer to: «INSTRUMENTATION, MESSAGE CENTER AND WARNING CHIMES»(ref-658834-S40402515032014092900000) . If any other PCM DTCs are retrieved, Refer to: «ELECTRONIC ENGINE CONTROLS»(ref-658891-S10303452132014092900000) .
3. B3 CHECK FOR AN AIRFLOW OBSTRUCTION AND MISSING AIR DEFLECTORS NOTE: Verify no vehicle front end damage is present. Check the radiator or A/C condenser for an external obstruction such as leaves or cardboard and verify all air deflectors are present. Is an airflow obstruction present or air deflectors missing? Yes : REPAIR as necessary. No : Go to B4
4. B4 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE COOLING SYSTEM Ignition OFF. Visually check the engine coolant level in the coolant expansion tank 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 B5
5. B5 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the coolant expansion tank for signs of engine oil. Is engine oil evident in the coolant? Yes : Refer to: «ENGINE»(ref-658863-S16845662912014092900000) .. No : Go to B6
6. B6 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-658863-S16845662912014092900000) .. No : Vehicles with an automatic transmission, Go to B7 Vehicles with a manual transmission, Go to B9
7. B7 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID Check the engine coolant in the degas bottle for signs of transmission fluid. Is transmission fluid evident in the engine coolant? Yes : INSTALL a new transmission cooler - warmer. Refer to: «TRANSMISSION FLUID COOLER - 6-SPEED AUTOMATIC TRANSMISSION - 6F35»(ref-658912-S39708602682014092900000) . REPAIR the transmission as necessary. Refer to: «AUTOMATIC TRANSMISSION - 2.0L ECOBOOST (177KW/240PS) - MI4»(ref-658852-S20169484962014092900000) . TEST the system for normal operation. No : Go to B8
8. B8 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT Remove the transmission oil leveling plug. Check the transmission fluid for engine coolant. Is engine coolant evident in the transmission fluid? Yes : INSTALL a new transmission cooler - warmer. Refer to: «TRANSMISSION FLUID COOLER - 6-SPEED AUTOMATIC TRANSMISSION - 6F35»(ref-658912-S39708602682014092900000) . REPAIR the transmission as necessary. Refer to: «AUTOMATIC TRANSMISSION - 2.0L ECOBOOST (177KW/240PS) - MI4»(ref-658852-S20169484962014092900000) . TEST the system for normal operation. No : Go to B9
9. B9 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-658863-S16845662912014092900000) .. 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 : Go to B11 No : FLUSH the engine cooling system. Refer to: «COOLING SYSTEM FLUSHING»(ref-658854-S20561608032014092900000) .
11. B11 CHECK THE ELECTRIC COOLING FAN OPERATION 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 : Go to B12 No : DIAGNOSE the electric cooling fan operation. Refer to «ENGINE CONTROLS - SYMPTOM CHARTS (EXCEPT DIESEL & HYBRID) (SECTION 3)»(ref-608993)
12. B12 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 B13 No : INSTALL a new coolant pump. Refer to: «COOLANT PUMP»(ref-658854-S13933959262014092900000) .
13. B13 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-658834-S40402515032014092900000) . No : Go to B14
14. B14 VISUALLY INSPECT THE THERMOSTAT Carry out the «THERMOSTAT VISUAL INSPECTION»(ref-658854-S12430588182014092900000) . Is the thermostat damaged? Yes : INSTALL a new thermostat housing. Refer to: «THERMOSTAT HOUSING»(ref-658854-S27679469962014092900000) . No : INSTALL a new thermostat housing. Refer to: «THERMOSTAT HOUSING»(ref-658854-S27679469962014092900000) . If the engine still overheats, INSTALL a new radiator. Refer to: «RADIATOR»(ref-658854-S17803708472014092900000) .

PINPOINT TEST C: PINPOINT TEST

1. C1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «INSPECTION AND VERIFICATION»(ref-658854-S32687014002014092900000) procedure. 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-658834-S40402515032014092900000) . If an inoperative climate control system is suspected, CHECK the climate control system operation. For Dual Automatic Temperature Control Refer to: «CLIMATE CONTROL SYSTEM - VEHICLES WITH: DUAL AUTOMATIC TEMPERATURE CONTROL (DATC)»(ref-658833-S04677658522014092900000) . For Electronic Manual Temperature control (EMTC) Refer to: «CLIMATE CONTROL SYSTEM - VEHICLES WITH: ELECTRONIC MANUAL TEMPERATURE CONTROL (EMTC)»(ref-658833-S05341070082014092900000) . If any other Diagnostic Trouble Codes (DTCs) are retrieved, Refer to: «ELECTRONIC ENGINE CONTROLS»(ref-658891-S10303452132014092900000) .
3. C3 CHECK THE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant expansion tank. Visually check the engine coolant level in the coolant expansion tank Is the engine coolant level within specification? Yes : INSTALL a new thermostat housing. Refer to: «THERMOSTAT HOUSING»(ref-658854-S27679469962014092900000) . CLEAR Diagnostic Trouble Codes (DTCs). If the DTC returns check for correct CHT sensor and ECT sensor operation. No : Go to «PINPOINT TEST A»(ref-658854-S40904736222014092900000)

Cooling System Pressure Test

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

Scheme 28

1. Turn the engine OFF.
2. Check the engine coolant level and adjust as necessary.
3. Remove the degas bottle cap. Inspect the degas bottle cap and degas bottle for any issues that would cause improper sealing, such as for cross-threading, burrs, damaged o-ring, etc. If any issues are found, INSTALL a new cap and/or degas bottle.
4. Attach the Pressure Tester and adaptor (Snap-On TA53 or equivalent), to the degas bottle cap. The cap must hold pressure of 145 kPa +/- 21 kPa (21 PSI +/- 3 PSI). If any issues are found, INSTALL a new cap.
5. If necessary, remove the cowl panel. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .
6. Attach the Pressure Tester and adaptor (Snap-On TA52, AST ASSFZ-47, Redline RDL95-0750 or equivalent) to the degas bottle. NOTE: Do not pressurize the cooling system beyond the maximum pressure listed in the specifications table, or cooling system components can be damaged. NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading will result.
7. To pressurize the engine cooling system, slowly press the plunger of the pressure test pump and increase the pressure to between 124 - 138 kPa (18 - 20 PSI). 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.
8. If no leaks are found 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-658863-S16845662912014092900000) ..
9. If the pressure does not drop remove the cooling system Pressure Tester and adaptor from degas bottle.
10. Install the degas bottle cap until it contacts the hard stop.
11. If necessary, install the cowl panel. Refer to: «COWL PANEL»(ref-658872-S27388717752014092900000) .

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. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot water or other heat sources. This method is not an accurate means to test the function of the thermostat and may damage the thermostat. 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.