Ford Falcon. Manual - part 169

303-03-3 Engine 

Cooling 303-03-3

DESCRIPTION AND OPERATION

Water Pump

Engine Cooling

A centrifugal-type water pump is mounted on the front

Radiator

of the cylinder block.

The radiators are of the tube and fin-core type with

A vane-type impeller supplies coolant through

the tubes arranged for horizontal coolant flow.

centrifugal action to the water pump oitlet port.

Two header tanks, one at each end of the core

If the pump is found to be faulty remove and discard

provide uniform distribution of the coolant to the

as it is of a sealed unit type which cannot be repaired.

tubes. The radiator outlet port is connected to the

Cooling System

water pump inlet port. The radiator inlet port is

connected to the coolant outlet housing of the engine, The cooling system operates as follows:

thereby permitting coolant circulation through the

Coolant flows through the radiator tubes and is

radiator when the thermostat is open.

cooled by air passing over the cooling fins

Midway down the right hand side radiator header tank

assisted by the radiator electric fans.

is the coolant supply tank feed port, this connects the

Coolant expands as the temperature and

cooling system with the supply tank. The supply tank

pressure rise in the system.

provides a chamber to accommodate the expansion

of the coolant as engine temperature increases.

When the limiting system working pressure is

reached, the pressure relief valve in the supply

A small port is located at the top of the right hand side

cap is lifted from its seat and allows coolant to

tank. It is connected to the top of the supply tank. This

flow through the supply tank overflow channel.

port aids the self purging of air from the cooling

system.

The supply tank cap has a rubber seal on the

underside to prevent leakage.

An oil cooler is located in the radiator outlet

header-tank to cool transmission fluid for automatic

When the system temperature and pressure drop,

transmission vehicles.

the coolant contracts in volume and the pressure

in the radiator is reduced.

A draincock is located at the bottom of the left hand

side tank.

 WARNING: Never remove the supply tank cap

The coolant supply tank cap incorporates a 120 kPa

under any conditions while the engine is

(18 psi) pressure relief valve and vacuum valve. For

operating. Failure to follow these instructions

routine coolant level inspections the tank provides a

could result in damage to the cooling system or

quick visual method for determining the coolant level

engine and/or personal injury. To avoid having

without removing the tanks cap.

scalding hot coolant or steam blow out of the

Should the coolant level exceed the capacity of the

supply tank, use extreme care when removing the

header tank it is discharged out the overflow channel. supply tank cap from a hot supply tank. Wait until

The header should not be overfilled.

the engine has cooled, try squeezing the upper

radiator hose to determine if the system is still

With the engine cold the level of coolant in the supply

under pressure. Then wrap a thick cloth around

tank should between the max and min lines on the

the supply tank cap and turn it slowly. Step back

supply tank.

while the pressure is released from the cooling

Electric Fans

system.

When certain all the pressure has been released,

The vehicle is fitted with dual electric fans controlled

turn the supply tank cap (still with a cloth), and

by three relays linked to the PCM module.

remove it.

During service operations, ensure that fan is not

rotated in a direction opposing normal operation as

 WARNING: The engine radiator electric fans

this may damage the motor (refer to arrow on fan

may come on at any time without warning.

blade).

Disconnect battery ground cable before servicing

Two operating modes are used (excluding OFF)

- this will clear diagnostic trouble codes and

depending on the status of the three relays

adaptive learning. The vehicle must then be driven

(determined by the PCM module). The different

for 30 mins and idled for 15 mins to relearn.

operating modes provide different cooling capabilities. (suggest using a 9 volt memory minder in the

cigar lighter to retain keep alive memory).

Refer to Wiring Diagrams section for a schematic of

the Fan Control System.

Cooling Maintenance

 CAUTION: When the ignition is in the ON

Correct coolant level is essential for maximum

position the fans may start without warning.

circulation and adequate cooling. In addition, for the

cooling system to perform its function it must receive

proper care. This includes maintaining corrosion

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303-03-4 Engine 

Cooling 303-03-4

DESCRIPTION AND OPERATION (Continued)

protection, keeping radiator fins clean, and periodic

in toxic amounts on repeated or prolonged skin

inspection of the cooling system for leakage.

contact. To promote the safe handling of coolant

the following precautions should be adhered to:

Use care when removing the supply tank to avoid

injury from escaping steam or hot water.

Maintain adequate ventilation and do not

inhale vapours.

To prevent the build up of rust, sludge and other

foreign material in the cooling system, add the

Must never be taken internally. If accidentally

specified Corrosion Inhibitor at the intervals specified.

swallowed seek medical advice immediately.

If it is found necessary to remove build up of foreign

Avoid skin contact. In the event of accidental

material from the cylinder block or radiator owing to

spillage onto the skin, wash off as soon as

neglect of adding an inhibitor, use the specified

possible. If clothing is splashed it should be

radiator cleaner. Removal of such material restores

removed and washed to avoid prolonged skin

cooling efficiency and avoids over-heating.

contact.

In severe cases where cleaning solvents will not

Avoid spillage on vehicle paint work. Wash off

properly clean the cooling system for efficient

immediately with water.

operation, it will be necessary to use the pressure

flushing method.
Various types of flushing equipment are available. If

pressure flushing is used, make sure the cylinder

head bolts are properly tightened to prevent possible

water leakage into the cylinders.
NOTE: Always remove the thermostat prior to

pressure flushing the engine.

When pressure flushing the engine or radiator, flush in

the reverse direction to normal water flow.
A pulsating or reversed direction of flushing water will

loosen sediment more quickly than a steady flow in

the normal direction of coolant flow.
The pressure applied to the radiator must not exceed

the supply tank cap relief pressure.
The coolant is water plus corrosion inhibitor and

Ethylene Glycol antifreeze (Motorcraft R1-33) Refer to

specifications.

 CAUTION: Motorcraft R1-33 is not compatible

with soluble oil or soluble oil based additives, or

leak-stop additives. Do not use these other

additives in the vehicle’s cooling system.
If any of these other additives have been added to the

coolant, the system must be drained and cleaned with

Motorcraft radiator cleaner R1-5 and then thoroughly

reverse flushed before refilling with clean water and

the specified quantity of Motorcraft R1-33. Refer to

“DRAINING AND FILLING THE COOLING SYSTEM”

in this part.

 WARNING: Do not remove the coolant supply

cap when the engine is hot. Allow the engine to

cool before removing the cap. Even then use

extreme care when removing the cap; wrap a thick

cloth around the cap and turn it slowly. Step back

while pressure is released from the cooling

system. When sure that all pressure has been

released, using the cloth, remove the cap.

 WARNING: Motorcraft R1-33

Anti-Freeze/Anti-Boil Concentrate contains

ethylene glycol and/or other constituents which

are toxic if taken internally and can be absorbed

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303-03-5 Engine 

Cooling 303-03-5

DIAGNOSIS AND TESTING

Engine Cooling

Visual Inspection Chart

Special Tool(s)

Mechanical

Electrical

Radiator Cap/Cooling System

Pressure Tester

Damaged hoses.

Circuitry

Available Commercially E 9353

Loose/damaged hose

open/shorted.

(Litchfield Tools)

clamps.

Damaged fan control

Damaged thermostat.

relays

Constant Tension Clamp Tool

Damaged head

Damaged radiator

Drive Belt

gaskets.

electric motor, fan

Available Commercially E 9353

Damaged water

blade and fan shroud

(Litchfield Tools)

pump.

assembly.

Damaged radiator.

Damaged or faulty

Inspection and Verification

Damaged supply tank

PCM.

Damaged heater core.

Open circuit in FAN 2

1.  Verify the concern by operating the engine cooling

motor.

system to duplicate the concern.

2.  Inspect to determine if one of the following

3.  If the concern(s) remains after the inspection,

mechanical or electrical concerns apply:

determine the symptom(s) and proceed to the

following Symptom Chart.

Symptom Chart

Condition

Source

Action

Damaged radiator.

  Loss of Engine Coolant

  Go to Test A.

Damaged water pump.
Loose/damaged radiator hoses.
Loose/damaged heater hoses.
Damaged heater core.
Damaged engine gaskets.
Damaged supply tank.
Demaged cap relief valve.
Demaged drain cock.

Damaged thermostat.

  Engine Overheats

  Go to Test B.

Damaged water pump.
Internal engine coolant leak.
Cooling fans inoperative.
Radiator coolant flow obstruction
(internal)
Radiator air flow obstruction (external
fins)
Heater core blocked.
Openings or grille blocked.
Damaged or faulty PCM.
Airlock in system

  Engine Does Not Reach Normal

Damaged thermostat.

  Go to Test C.

Cooling fans, PCM fault.

Operating Temperature

Low engine coolant.

  CHECK bolt torques. Perform pressure

  Water pump leaking

Gasket (leak at pump/block interface)

test both statically and dynamically
and visually confirm leak. REPLACE
water pump if necessary.

  Perform pressure test both statically

O-Ring (leak at heater tube)

and dynamically and visually confirm
leak. REPLACE O-Ring.

  A small amount of weep through this

Weep hole

hole is considered normal and
acceptable. Perform pressure test both
statically and dynamically and visually
confirm leak. REPLACE water pump if
necessary.

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303-03-6 Engine 

Cooling 303-03-6

DIAGNOSIS AND TESTING (Continued)

Tests

TEST A : LOSS OF COOLANT

Test Step

Result/Action to Take

A1

CHECK COOLANT LEVEL

Yes

NOTE: If engine is hot, allow engine to cool down before

Go to A2

proceeding.

No

Check coolant level coolant supply tank.

REFILL coolant.

Is coolant level OK?

Go to A2

A2

CHECK FOR VISIBLE LEAKAGE

Engine coolant has an added dye colour that makes the

Yes

coolant an excellent leak detector.

Rectify leak.

Check entire cooling system for visible leakage.

RETEST system.

Is there visible leakage?

No

Go to A3

A3

CHECK SUPPLY TANK CAP

Using a Radiator/Heater Core Pressure Tester test

Yes

radiator cap as outlined in this section.

Go to A4

Did supply tank cap test OK?

No

REPLACE damaged supply tank cap.

RETEST system.

A4

CHECK COOLANT FOR INTERNAL LEAKAGE

Visually inspect coolant in radiator and coolant supply

Yes

tank for signs of transmission or engine oil.

If engine oil is evident, Go to Section

Is oil evident in coolant?

308-03.

If transmission oil is evident, Go to

Section 307-01 or Section 308-03.

No

Go to A5

A5

CHECK ENGINE AND TRANSMISSION FOR COOLANT

Remove oil level indicator from engine and transmission. Yes

Carefully inspect oil level indicator for evidence of

If coolant is in engine, Go to Section

coolant.

303-00.

Is coolant evident?

If coolant is in transmission, Go to

Section 307-01 or Section 308-03.

No

Go to A6

A6

PRESSURE TEST COOLING SYSTEM

Yes

NOTE: Check inside vehicle for possible heater core

Rectify leak.

leakage.

RETEST system.

Using a Radiator/Heater Core Pressure Tester conduct a No

pressure test.

Cooling system is operational at this

Check for any signs of visible leakage.

time.

Is there leakage?

RETEST system.

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