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Engine Cooling System - 2.5L: Other Ford Kuga II

Cooling System (Mechanical) 4 illustrations ~700 words

Cooling System Pressure

Complete cooling system maximim pressure150 kPa (21.7 psi)
Pressure relief cap120 kPa (17.4 psi) to 150 kPa (21.7 psi)
Radiator pressure test (removed from the vehicle)138 kPa (20 psi)

Thermostat Opening Temperatures

Starts to open90°C (194°F)
Fully open106°C (223°F)

Scheme 66

Scheme 66: Engine Cooling - Component Location
Scheme 66: Engine Cooling - Component Location
ItemDescription
1Pressure relief cap
2Degas bottle
3Transmission fluid cooler coolant control valve inlet hose
4Upper radiator hose
5Radiator
6Transmission fluid cooler coolant control valve
7Transmission fluid cooler coolant control valve outlet hose assembly
8Degas bottle-to-thermostat housing hose assembly
9Lower radiator hose
10Engine block
11Thermostat housing
12Coolant bypass hose connector
13Cylinder head gasket
14Coolant pump
15Cylinder head
16Degas bottle-to-radiator hose assembly
17Heater core inlet hose assembly
18Heater core
19Heater core outlet hose
20EGR valve
21Coolant outlet connector adapter assembly
22Coolant bypass hose
23Transmission fluid cooler - warmer
24Transmission fluid heater coolant control valve

Fail Safe Cooling

A strategy called Fail Safe Cooling is built into the PCM that will control the engine if it starts to overheat.

Stage 1 of the strategy commences if the engine starts to overheat. The CHT sensor transmits a signal to the PCM , which 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 which can be retrieved using a scan tool.

Stage 2 of the strategy commences if the lamp and temperature gauge are ignored by the driver. The PCM will start to control the engine by cutting out 2 cylinders and restricting the RPM to below 3, 000 RPM. Simultaneously the MIL illuminates. This indicates that long term engine damage can 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. This 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 scan tool after the fault has been rectified and the DTC cleared.

Stage 3 of the strategy will commence if the engine temperature continues to rise. This results 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.

Possible Sources

  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. Radiator
  7. Pressure relief cap
  8. Coolant pump leaking from weep hole
  9. Heater core
  10. Engine gaskets (may leak internally or externally)
  11. Degas bottle
  12. Transmission fluid heater coolant control valve
  13. Transmission fluid cooler coolant control valve
  14. Transmission fluid cooler - warmer (may leak internally or externally)
  15. Cylinder block core plugs
  16. Cylinder head core plugs
  17. Block heater (if equipped)
  1. Low coolant level
  2. External engine coolant leak
  3. Airlock in system
  4. Pressure relief cap installation
  5. Restricted airflow through A/C condenser/radiator
  6. Internal engine coolant leak
  7. Transmission fluid cooler
  8. Turbocharger
  9. Coolant condition/concentration
  10. Non-OEM engine enhancement components
  11. Electric cooling fan
  12. CHT sensor
  13. Radiator
  14. Thermostat
  15. Coolant pump
  16. Coolant flow restriction
DTCDescriptionFault Trigger Conditions
P0217Engine Coolant Overtemperature ConditionSets in the PCM when an engine overheat condition was sensed by the CHT sensor or the ECT sensor.
P1299Cylinder Head Overtemperature Protection ActiveSets in the PCM when an engine overheat condition was sensed by the CHT sensor or the ECT sensor. A failure mode effects strategy called fail-safe cooling was activated to cool the engine.

DTC FAULT TRIGGER CONDITION

  1. Low coolant level
  2. Thermostat
  3. Temperature gauge
  4. CHT
DTCDescriptionFault Trigger Conditions
P0125Insufficient Coolant Temp for Closed Loop Fuel ControlSets in the PCM when the CHT sensor or the ECT sensor has not achieved the required temperature level to enter closed loop operating conditions within a specified amount of time after starting the engine.
P0128Coolant Thermostat (Coolant Temp Below Thermostat Regulating Temperature)Sets in the PCM when the thermostat monitor has not achieved the required engine operating temperature within a specified amount of time after starting the engine.

DTC FAULT TRIGGER CONDITION

Thermostat

Install a new thermostat only after at least one of the following tests and checks have been carried out

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

Filling

Filling and Bleeding with a Vacuum Cooling System Filler

Pinpoint Test C

C1 ROB75240 Coolant/Battery Refractometer (Fahrenheit)
C22 Filling and Bleeding without a Vacuum Cooling System Filler
  1. Filling and Bleeding without a Vacuum Cooling System Filler
C23 ROB75240 Coolant/Battery Refractometer (Fahrenheit)

Coolant Pump

NameSpecification
Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.) VC-3-B (U.S.)WSS-M97B44-D

MATERIAL SPECIFICATION

Scheme 67

Scheme 67: Removal
Scheme 67: Removal

Scheme 68

Scheme 68
Scheme 68
  1. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658855-S14452308552014092900000) .

Scheme 69

Scheme 69: Installation
Scheme 69: Installation
  1. Material: Motorcraft® Orange Antifreeze/Coolant Concentrated (U.S.)/VC-3-B (U.S.) (WSS-M97B44-D) Torque: 89 lb.in (10 Nm)
  2. Torque: 177 lb.in (20 Nm)
  3. Refer to: «COOLING SYSTEM DRAINING AND VACUUM FILLING»(ref-658855-S14452308552014092900000) .

Cooling Module

Special Tool(s)/General Equipment

Hose Clamp Remover/Installer

Cooling Fan Motor and Shroud

Special Tool(s)/General Equipment

Hose Clamp Remover/Installer

Degas Bottle

Fluid Suction Gun
Hose Clamp(s)
Locking Pliers

SPECIAL TOOL DESCRIPTION

Radiator

Hose Clamp Remover/Installer
Knife

SPECIAL TOOL DESCRIPTION

Thermostat Housing

Special Tool(s)/General Equipment

Hose Clamp Remover/Installer

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