Engine Cooling System Ford Transit Connect I рестайлинг

Material Specifications

MATERIAL SPECIFICATIONS

General Specifications

GENERAL SPECIFICATIONS TABLE

Torque Specifications

TORQUE SPECIFICATIONS

Note. The engine cooling system is filled with Motorcraft® Specialty Orange Engine Coolant. Mixing coolant types degrades the corrosion protection of Motorcraft® Specialty Orange Engine Coolant. Do not mix coolant types. Failure to follow this instruction may result in engine or cooling system damage.

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.

Note. The addition of Cooling System Stop Leak Pellets darkens the coolant.

Note. During normal vehicle operation, Motorcraft Specialty Orange Engine 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.

The cooling system consists of the

1. radiator.
2. cooling fan motor and shroud.
3. degas bottle.
4. radiator drain valve.
5. coolant pump.
6. thermostat housing.
7. block heater (if equipped).

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. A coolant concentration of 50% provides freeze point protection down to -37°C (-34°F).

To maintain the integrity of the coolant and the cooling system

1. Add Motorcraft® Specialty Orange Engine Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of the original coolant.
2. Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
3. Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles.

Fail-Safe Cooling

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 which 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 2 cylinders and restricting the rpm to below 3,000 rpm. Simultaneously the Malfunction Indicator Lamp (MIL) will be illuminated. 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 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.

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 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.

Scheme 1

ITEM DESCRIPTION

Special Tool(s)

SPECIAL TOOLS 3-Way HD Antifreeze Coolant Test Kit 328-00001 or equivalent Coolant/Battery Refractometer ROB75240 or equivalent D-Gas Adapter 300-OTC014-R1068 or equivalent Radiator Tester STN12270 or equivalent UView® Combustion Leak Tester UVU560000-R or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware or equivalent scan tool

Scheme 2

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Material Specification

MATERIAL SPECIFICATIONS

Principles of Operation

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core and turbochargers with coolant. The coolant pump, operated by engine rotation through a sprocket which is driven by the timing chain, circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit to transfer engine-generated heat to the outside air.

The degas bottle holds surplus coolant and removes air from the cooling system, which reduces hot spots. It also allows for coolant expansion and system pressurization, replenishes coolant to the cooling system and serves as the location for service fill.

The cooling fan draws air through the radiator to help cool the system coolant as it passes through the radiator.

The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation. The monitor executes once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction occurs, DTC P0125 or P0128 is set, and the Malfunction Indicator Lamp (MIL) is illuminated.

For engine specific information, refer to ENGINE COOLING in the Description and Operation portion of this service information.

Inspection and Verification

Note. The engine cooling system is filled with Motorcraft® Specialty Orange Engine 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 in this service information. Failure to follow these instructions may damage the engine or cooling system.

Note. The engine cooling system is filled with Motorcraft® Specialty Orange Engine Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of the original coolant. Failure to follow these instructions may result in engine or cooling system damage

Note. During normal vehicle operation, Motorcraft Specialty Orange Engine 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 DTCs retrieved. Refer to the «PCM DTC CHART»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__pcm-dtc-chart) in this service information for DTC descriptions.
5. If the system coolant is filled correctly and no 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 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) Oil cooler Degas bottle Cylinder block core plugs Cylinder head core plugs Block heater (if equipped) Inoperative or damaged: Electric cooling fan Wiring, connectors, relays or modules Cylinder Head Temperature (CHT) sensor Vehicle Speed Sensor (VSS) Cracked or damaged: Hoses Tubes Hose clamps Thermostat housing Radiator Pressure relief cap Cooling fan Coolant pump Oil cooler Degas bottle 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
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 in the following sequence: Inspect the coolant appearance. 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® Specialty Orange Engine 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 Coolant, however, may not change the color or appearance of the orange colored coolant. Detection of contamination with Premium Gold Engine Coolant is determined by the presence of nitrite. If contamination with Motorcraft® Premium Gold Engine Coolant is suspected, test the coolant with the 3-Way HD Antifreeze Coolant Test Kit. Follow the directions in/on the packaging with regard to nitrite testing. If the incorrect coolant has been added to the cooling system (nitrite is present), flush the system and refill with the correct mixture of distilled water and Motorcraft® Specialty Orange Engine Coolant. Refer to «COOLING SYSTEM FLUSHING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information. 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 in the coolant sample, flush the system and refill with the correct mixture of distilled water and Motorcraft® Specialty Orange Engine Coolant. Refer to «COOLING SYSTEM FLUSHING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information. A light or reddish brown color or reddish brown particles indicate that rust may be present in the cooling system. Flush the system and refill with the correct mixture of distilled water and the correct engine coolant. Refer to «COOLING SYSTEM FLUSHING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information. 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 MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article. A milky color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to «COMPONENT TESTS»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information. If engine oil is suspected, the cause of the leak may be internal to the engine. Refer to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article. If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the Coolant/Battery Refractometer. The freezing point should be in the range -50°C to -26°C (-58°F to -15°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 50/50 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 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 «MODULE COMMUNICATIONS NETWORK»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#module-communications-network) article, No Power To The Scan Tool, to diagnose no power to 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 «MODULE COMMUNICATIONS NETWORK»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#module-communications-network) article to diagnose no response from the PCM.
13. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/transit-connect/i-2009-2013/remont/communication-devices/#module-communications-network) article. If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes (CMDTCs).
14. Clear the continuous DTCs and carry out the self-test diagnostics PCM.
15. If the DTCs recovered are related to the concern, go to the «PCM DTC CHART»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__pcm-dtc-chart) . For all other DTCs, refer to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article.
16. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__symptom-chart) .

PCM DTC Chart

PCM DTC CHART

Symptom Chart

SYMPTOM CHART

Normal Operation

The engine cooling system is a closed system providing for coolant expansion and contraction and also changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the cooling system.

Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.

For engine specific information, refer to ENGINE COOLING in the Description and Operation portion of this service information.

This pinpoint test is intended to diagnose the following

1. Coolant hoses or tubes
2. Hose clamps
3. Thermostat O-ring gasket
4. Coolant pump O-ring seal
5. Thermostat housing
6. Radiator
7. Pressure relief cap
8. Coolant pump leaking from weep hole
9. Oil cooler
10. Heater core
11. Engine gaskets
12. Degas bottle
13. Cylinder block core plugs
14. Cylinder head core plugs
15. Block heater (if equipped)

PINPOINT TEST A: LOSS OF COOLANT

1. A1 CARRY OUT INSPECTION AND VERIFICATION Carry out the Inspection and Verification procedure in this service information. 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. Ignition OFF. Visually inspect the engine coolant level at the degas bottle. Is the engine coolant level within the MIN/MAX fill marks? 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»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «COOLING SYSTEM PRESSURE TEST»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-pressure-test) in this service information. Does the engine cooling system leak externally? Yes: REPAIR or INSTALL new components. TEST the system for normal operation. No: GO to A4 .
4. A4 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: GO to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article for engine diagnosis. No: GO to A5 .
5. A5 CHECK THE ENGINE OIL FOR COOLANT Remove the oil level indicator from the engine. Is coolant evident in the oil? Yes: GO to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article for engine diagnosis. No: GO to A6 .
6. A6 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: GO to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article for engine diagnosis. No: The cooling system is operational.

The engine cooling system maintains engine temperatures during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump, operated by engine rotation through a pulley which is driven by the accessory drive belt, circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine-generated heat to the outside air.

Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at the correct rate, the inability to transfer heat from the engine through the coolant (including low coolant) or an inability to transfer engine generated heat to the outside air through the radiator.

For engine specific information, refer to ENGINE COOLING in the Description and Operation portion of this service information.

1. DTC P1285:00 (Cylinder Head Overtemperature Condition: No Sub Type Information) - Indicates an engine overheat condition was sensed by the Cylinder Head Temperature (CHT) sensor.
2. DTC P1288:00 (Cylinder Head Temperature (CHT) Sensor Out of Self-Test Range: No Sub Type Information) - Indicates the CHT sensor is out of self-test range. The engine is not at a normal operating temperature.
3. DTC P1299:00 (Cylinder Head Overtemperature Protection Active: No Sub Type Information) - Indicates an engine overheat condition was detected by the CHT sensor. A failure mode effects management strategy called fail-safe cooling was activated to cool the engine.

This pinpoint test is intended to diagnose the following

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
11. Engine Coolant Temperature (ECT) gauge
12. CHT sensor
13. Heater core
14. Coolant pump
15. Coolant flow restriction

PINPOINT TEST B: THE ENGINE OVERHEATS

1. B1 CARRY OUT INSPECTION AND VERIFICATION Carry out the Inspection and Verification procedure in this service information. Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to B2 .
2. B2 CHECK FOR DTC P1285:00, P1288:00 or P1299:00 Check for DTC P1285:00, P1288:00 or P1299:00. Is DTC P1285:00, P1288:00 or P1299:00 present? Yes: GO to B3 . No: Actual engine overheating has not been verified. CHECK the ECT gauge operation. REFER to «INSTRUMENTATION & WARNING CHIMES»(/ford/transit-connect/i-2009-2013/remont/gauges-instrument-panels/#instrumentation-warning-chimes) article. If any other PCM DTCs are retrieved, REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article.
3. B3 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. 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. Ignition OFF. Visually check the engine coolant level in the degas bottle. Is the engine coolant level within the MIN/MAX fill marks? 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»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) , «COOLING SYSTEM PRESSURE TEST»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-pressure-test) in this service information. Does the engine cooling system leak externally? Yes: REPAIR or INSTALL new components. TEST the system for normal operation. No: GO to B6 .
6. B6 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: GO to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article for engine diagnosis. No: GO to B7 .
7. B7 CHECK THE ENGINE OIL FOR COOLANT Remove the oil level indicator from the engine. Is coolant evident in the oil? Yes: GO to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article for engine diagnosis. No: GO to B8 .
8. B8 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: GO to «ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article for engine diagnosis. No: GO to B9 .
9. B9 CHECK COOLANT CONDITION Check the coolant for dirt, rust or contamination and check the coolant concentration. Is the coolant condition OK? Yes: GO to B10 . No: FLUSH the engine cooling system. REFER to «COOLING SYSTEM FLUSHING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information. TEST the system for normal operation.
10. B10 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: GO to B11 . No: DIAGNOSE the electric cooling fan operation. REFER to «INTRODUCTION»(/ford/transit-connect/i-2009-2013/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article.
11. B11 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 B12 . No: INSTALL a new coolant pump. TEST the system for normal operation.
12. B12 CHECK THE THERMOSTAT OPERATION Start the engine. Allow the engine to run for 30 minutes. Feel the lower radiator hose. Is the lower radiator hose hot? Yes: CHECK the Engine Coolant Temperature (ECT) gauge operation. REFER to «INSTRUMENTATION & WARNING CHIMES»(/ford/transit-connect/i-2009-2013/remont/gauges-instrument-panels/#instrumentation-warning-chimes) article. No: GO to B13 .
13. B13 VISUALLY INSPECT THE THERMOSTAT Carry out the Thermostat Visual Inspection in the «Component Tests»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) portion of this service information. 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.

The engine cooling system maintains engine temperatures during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump, operated by engine rotation through a pulley which is driven by the accessory drive belt, circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit to transfer engine generated heat to the outside air.

Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant flow through some coolant circuits (radiator, heater core) is more than expected given the conditions, or when the electric cooling fans operate all the time. Heat is not allowed to build in the engine because a heat exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition, perceived concerns that the engine does not reach normal operating temperature can be related to a low coolant level or trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.

For engine specific information, refer to ENGINE COOLING in the Description and Operation portion of this service information.

1. DTC P0128:00 (Coolant Thermostat [Coolant Temp Below Thermostat Regulating Temperature]: No Sub Type Information) - Indicates that the thermostat monitor has not achieved the required engine operating temperature within a specified amount of time after starting the engine.

This pinpoint test is intended to diagnose the following

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 procedure in this service information. Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to C2 .
2. C2 CHECK FOR DTC P0128:00 Check for DTC P0128:00. Is DTC P0128:00 present? Yes: GO to C3 . No: The cooling system is operational. If an inoperative ECT gauge is suspected, CHECK the ECT gauge operation. REFER to «INSTRUMENTATION & WARNING CHIMES»(/ford/transit-connect/i-2009-2013/remont/gauges-instrument-panels/#instrumentation-warning-chimes) article. If an inoperative climate control system is suspected, CHECK the climate control system operation. REFER to «HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS»(/ford/transit-connect/i-2009-2013/remont/manual-hvac-system/#hvac-climate-control-system-general-information-diagnostics) article. If any other PCM DTCs are retrieved, REFER to «ELECTRONIC ENGINE CONTROL SYSTEM»(/ford/transit-connect/i-2009-2013/remont/removal-installation/#electronic-engine-control-system) article.
3. C3 CHECK THE ELECTRIC COOLING FAN OPERATION Allow the engine to cool. Make sure the A/C switch is OFF. 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»(/ford/transit-connect/i-2009-2013/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) article. No: GO to C4 .
4. C4 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. Is the engine coolant level within specification? Yes: INSTALL a new thermostat. TEST the system for normal operation. No: GO to «PINPOINT TEST A»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__pinpoint-test-a-loss-of-coolant) to diagnose a coolant leak.

Cooling System Pressure Test

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

Scheme 7

1. Turn the engine OFF.
2. Check the engine coolant level. Adjust the coolant level as necessary.
3. Attach the D-Gas Adapter to the degas bottle nipple and overflow hose. Install the Radiator Tester to the quick connect fitting of the D-Gas 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 «GENERAL SPECIFICATIONS TABLE»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) , 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 MECHANICAL SYSTEM - GENERAL INFORMATION»(/ford/transit-connect/i-2009-2013/remont/mechanical/#engine-mechanical-system-general-information) article to diagnose the engine.
9. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as necessary.

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

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 Bent or broken valve or valve stem 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.
4. If no damage is found during the inspection, continue troubleshooting the system concern. Go to the «SYMPTOM CHART»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__symptom-chart) for further instructions.

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.

Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the specifications.

SPECIAL TOOLS Airlift Cooling System Tester UVU550000 or equivalent

Scheme 8

MATERIAL SPECIFICATIONS

Draining

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn counterclockwise. When the pressure is released, remove the pressure relief cap.
3. Place a suitable container below the radiator drain valve. Open the radiator drain valve and allow the coolant to drain. Close the radiator drain valve.

Filling and Bleeding with a Vacuum Cooling System Filler

Note. Engine coolant provides boil protection, corrosion protection, freeze protection, and cooling efficiency to the engine and cooling components. In order to obtain these protections, maintain the engine coolant at the correct concentration and fluid level in the degas bottle. To maintain the integrity of the coolant and the cooling system: Add Motorcraft® Specialty Orange Engine Coolant or equivalent meeting Ford specification WSS-M97B44-D. Do not mix coolant types. Do not add or mix with any other type of 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® Specialty Orange Engine Coolant since a Ford-approved recycling process is not yet available.

Scheme 9

1. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill and bleed the cooling system. Recommended coolant concentration is 50/50 engine coolant to distilled water. For extremely cold climates (less than -37°C [-34°F]): It may be necessary to increase the coolant concentration above 50%. NEVER increase the coolant concentration above 60%. Maximum coolant concentration is 60/40 for cold weather areas. A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F). Engine coolant concentration above 60% decreases the overheat protection characteristics of the engine coolant and may damage the engine. For extremely hot climates: It is still necessary to maintain the coolant concentration above 40%. NEVER decrease the coolant concentration below 40%. Minimum coolant concentration is 40/60 for warm weather areas. A coolant concentration of 40% provides freeze point protection down to -26°C (-15°F). Engine coolant concentration below 40% decreases the corrosion and freeze protection characteristics of the engine coolant and may damage the engine. Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine coolant and distilled water for optimum cooling system and engine protection.

Filling and Bleeding without RADIATOR REFILLER

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. To maintain the integrity of the coolant and the cooling system: Vehicle cooling systems are filled with Motorcraft® Specialty Orange Engine Coolant. Do not mix coolant types. 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.

1. Fill the degas bottle to the max level mark. Recommended coolant concentration is 50/50 engine coolant to distilled water. For extremely cold climates (less than -37°C [-34°F]): It may be necessary to increase the coolant concentration above 50%. NEVER increase the coolant concentration above 60%. Maximum coolant concentration is 60/40 for cold weather areas. A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F). Engine coolant concentration above 60% decreases the overheat protection characteristics of the engine coolant and may damage the engine. For extremely hot climates: It is still necessary to maintain the coolant concentration above 40%. NEVER decrease the coolant concentration below 40%. Minimum coolant concentration is 40/60 for warm weather areas. A coolant concentration of 40% provides freeze point protection down to -26°C (-15°F). Engine coolant concentration below 40% decreases the corrosion and freeze protection characteristics of the engine coolant and may damage the engine. Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine coolant and distilled water for optimum cooling system and engine protection.
2. Install the degas bottle pressure relief cap.
3. Start the engine, run and hold at 2,500 rpm for approximately 8 minutes until the thermostat opens, then for another 3 minutes after the thermostat opens.
4. Increase the engine speed briefly to 4,000 rpm and hold for approximately 5 seconds.
5. Return the engine speed to 2,500 rpm and hold for another 3 minutes.
6. Shut the engine OFF and allow to cool.
7. Check the engine for any leaks.
8. Check the coolant level in the degas bottle and fill to the MAX fill line as necessary.

MATERIAL SPECIFICATIONS

Note. To remove rust, sludge and other foreign material from the cooling system, use cooling system flush that is safe for use with aluminum radiators. For additional information, refer to SPECIFICATIONS . This cleaning restores cooling system efficiency and helps prevent overheating. A pulsating or reversed direction of flushing water will loosen sediment more quickly than a steady flow in the normal coolant flow direction. In severe cases where cleaning solvents will not clean the cooling system efficiently, it will be necessary to use the pressure flushing method using cooling system flusher. Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.

1. Add premium cooling system flush to the cooling system and follow the directions on the package.
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
3. Remove the radiator. For additional information, refer to «RADIATOR»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__radiator-leak-test-removed-from-vehicle) in this service information.
4. Backflush the radiator with the radiator in an upside-down position and a high-pressure hose in the lower hose location.
5. Remove the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
6. Position a high-pressure water hose into the engine through the upper radiator hose and backflush the engine.
7. Install the thermostat housing. For additional information, refer to «THERMOSTAT HOUSING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
8. Install the radiator. For additional information, refer to «RADIATOR»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system__radiator-leak-test-removed-from-vehicle) in this service information.
9. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.

MATERIAL SPECIFICATIONS

Scheme 10

ITEM DESCRIPTION

Removal and Installation

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

MATERIAL SPECIFICATIONS

Scheme 11

ITEM DESCRIPTION

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
2. Loosen the 3 coolant pump pulley bolts. To install, tighten to 20 Nm (177 lb-in).
3. Remove the accessory drive belt. For additional information, refer to «ENGINE ACCESSORY DRIVE BELTS»(/ford/transit-connect/i-2009-2013/remont/accessory-drive-belts/#accessory-drive-system) article.
4. Remove the 3 coolant pump pulley bolts and the pulley.
5. Remove the 3 coolant pump bolts and the coolant pump. To install, tighten to 10 Nm (89 lb-in).
6. To install, reverse the removal procedure.
7. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.

Scheme 12

ITEM DESCRIPTION

Scheme 13

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
2. Remove the 2 bolts, pin-type retainer and the LH front splash shield.
3. Disconnect the upper radiator and degas bottle hoses from the radiator.
4. Remove the cooling fan motor and shroud. For additional information, refer to «COOLING FAN MOTOR AND SHROUD»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
5. Remove the 2 cooling fan and shroud bolts from the radiator.
6. Remove the 4 pin-type retainers and position the lower air deflector aside.
7. Disconnect the lower radiator hose from the radiator.
8. Remove the A/C tube bracket nut from the RH side of the lower radiator support. To install, tighten 9 Nm (80 lb-in).
9. Position a jackstand below the lower radiator support to support the cooling module.
10. Remove the 4 bolts and the lower radiator support. To install, tighten 25 Nm (18 lb-ft).
11. Slide the radiator towards the LH side of vehicle to separate the radiator from the A/C condenser core and remove the radiator.
12. To install, reverse the removal procedure.
13. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.

Scheme 14

ITEM DESCRIPTION

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/transit-connect/i-2009-2013/remont/hoistjack/#jacking-lifting) article.
2. Disconnect the cooling fan motor and shroud resistor electrical connector.
3. Disconnect the RH and LH cooling fan motor electrical connector. Detach the LH cooling fan motor wiring harness pin-type retainer.
4. Remove the 2 nuts and the cooling fan motor and shroud. To install, tighten to 5 Nm (44 lb-in).
5. To install, reverse the removal procedure.

Scheme 15

ITEM DESCRIPTION

1. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.
2. Disconnect the block heater electrical connector.
3. Remove the block heater. To install, tighten to 40 Nm (30 lb-ft).
4. To install, reverse the removal procedure.
5. Fill and bleed the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) in this service information.

Scheme 16

ITEM DESCRIPTION

1. Release the pressure in the cooling system by slowly turning the pressure relief cap one-half turn counterclockwise. When the pressure is released, remove the pressure relief cap.
2. Using hose clamp pliers, clamp the lower degas bottle hose.
3. Using a suction device, siphon the coolant from the degas bottle.
4. Disconnect the degas bottle-to-radiator hose.
5. Disconnect the degas bottle-to-coolant outlet hose.
6. Disconnect the lower degas bottle hose-to-radiator.
7. Remove the degas bottle bolt. To install, tighten to 8 Nm (71 lb-in).
8. Release the degas bottle mounting bracket tab on the rear of the degas bottle and remove the degas bottle.
9. To install, reverse the removal procedure.
10. Fill the degas bottle. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/transit-connect/i-2009-2013/remont/cooling-system-mechanical/#engine-cooling-system) for the recommended coolant mixture and fill level.

See also:
• ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION
• MODULE COMMUNICATIONS NETWORK
• ELECTRONIC ENGINE CONTROL SYSTEM
• INTRODUCTION
• INSTRUMENTATION & WARNING CHIMES
• HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION & DIAGNOSTICS
• JACKING & LIFTING
• POWER STEERING SYSTEM SERVICING
• ENGINE ACCESSORY DRIVE BELTS
• ENGINE COOLING
• PCM DTC CHART
• SYMPTOM CHART
• PINPOINT TEST C
• PINPOINT TEST B
• PINPOINT TEST A
• COOLING SYSTEM PRESSURE TEST
• RADIATOR