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Ford Galaxy / Ford S-MAX. Manual - part 322

cap or seal(s).

necessary.

Coolant

expansion tank.

INSPECT the coolant expansion tank for damage.

INSTALL a new coolant expansion tank as necessary.

Coolant level or

condition.

CHECK the coolant level. REFILL the cooling system as

necessary.
REFER to:

Cooling System Draining, Filling and

Bleeding

(303-03A Engine Cooling - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, General Procedures).

CHECK the coolant condition. If the coolant is in poor

condition drain and refill with new coolant.
REFER to:

Cooling System Draining, Filling and

Bleeding

(303-03A Engine Cooling - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, General Procedures).

Coolant

concentration.

REFER to:

Specifications

(303-03A Engine Cooling -

2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Specifications).

Radiator grille.

INSPECT the radiator grille for air restrictions or

damage. REPAIR or INSTALL new parts as necessary.

Coolant pump.

CARRY OUT the Pressure Test Component Test in this

section. INSPECT the coolant pump for leaks. INSTALL
a new coolant pump or coolant pump gasket as
necessary.
REFER to:

Coolant Pump

(303-03A Engine Cooling -

2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

Thermostat.

CARRY OUT the Thermostat Test Component Test in

this section. INSTALL a new thermostat housing and
thermostat housing gasket as necessary.
REFER to:

Thermostat - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4

(303-03A Engine Cooling - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

Accessory drive

belt.

CHECK the condition of the accessory drive belt.

REFER to:

Accessory Drive

(303-05A Accessory Drive - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-
HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-
HE (118kW/160PS) - MI4, Diagnosis and Testing),

Accessory Drive

(303-05C Accessory Drive - 2.5L

Duratec (162kW/220PS) - VI5, Diagnosis and
Testing).

Cooling fan.

CHECK the operation of the cooling fan. REFER to the

Ford approved diagnostic tool.

Engine.

INSPECT the engine, cylinder head, cylinder block and

cylinder head gasket. REFER to:

Cylinder Head

(303-01A Engine - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4, Removal and Installation),

Cylinder Head

(303-01C Engine - 2.3L Duratec-HE

(118kW/160PS) - MI4, Removal and Installation).

The engine does

Thermostat.

CARRY OUT the Thermostat Test Component Test in

Component Tests

Pressure Test

WARNING: When releasing the cooling system pressure, cover the coolant expansion

tank cap with a thick cloth to prevent the possibility of coolant scalding. Failure to follow
this instruction may result in personal injury.
NOTE: If the coolant expansion tank cap is rotated counterclockwise by ½ a full turn, the
pressurized coolant will be vented to the underside of the coolant expansion tank cap.

1. 1. Slowly remove the coolant expansion tank cap to release the cooling system

pressure.

2. 2. Install the coolant expansion tank cap.

3. 3. Install the special tools 303-396 and 303-396-09 to the coolant expansion tank.

4. 4. Pressurize the cooling system to the coolant expansion tank cap release pressure.

REFER to:

Specifications

(303-03A Engine Cooling - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel (107kW/145PS) - MI4/2.3L
Duratec-HE (118kW/160PS) - MI4, Specifications).

5. 5. Observe the cooling system pressure tester gauge reading for approximately two

minutes. The pressure should not drop during this time. If the cooling system holds
pressure, proceed to Step 7. If the cooling system does not hold pressure, check it
thoroughly for coolant leaks.

6. 6. Check the engine for coolant leaks. Drain the cooling system, repair any coolant

leaks found and fill and bleed the cooling system as necessary.
REFER to:

Cooling System Draining, Filling and Bleeding

(303-03A Engine Cooling -

2.0L Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel (107kW/145PS) -
MI4/2.3L Duratec-HE (118kW/160PS) - MI4, General Procedures).

7. 7. Recheck the cooling system by repeating Steps 3 and 4 at least twice.

Radiator Leak Test, Removed From Vehicle

CAUTION: Radiator internal pressure must not exceed 130 kpa (20 psi) or damage

may result.

Clean the radiator thoroughly before leak testing it, to prevent contamination of the water
in the test tank. Leak test the radiator in clean water with 138 kpa (20 psi) air pressure.
Check it thoroughly for air leaks. INSTALL a new radiator if necessary.
REFER to:

Radiator

(303-03A Engine Cooling - 2.0L Duratec-HE (107kW/145PS) - MI4/2.0L

Duratec-HE Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE (118kW/160PS) - MI4,
Removal and Installation).

Coolant Expansion Tank Cap Pressure Test

not reach normal
operating
temperature.

this section. INSTALL a new thermostat housing and
thermostat housing gasket as necessary.
REFER to:

Thermostat - 2.0L Duratec-HE

(107kW/145PS) - MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4

(303-03A Engine Cooling - 2.0L

Duratec-HE (107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4/2.3L Duratec-HE
(118kW/160PS) - MI4, Removal and Installation).

WARNING: When releasing the cooling system pressure, cover the expansion tank

cap with a thick cloth to prevent the possibility of coolant scalding, Failure to follow this
instruction may result in personal injury.

1. 1. Remove the coolant expansion tank cap.

2. 2. Use water to clean the area of the rubber seal and pressure relief valve. Install the

pressure tester and adapter and immerse the coolant expansion tank cap in water .

NOTE: If the plunger of the pump is depressed too quickly, an erroneous pressure
reading will result.

3. 3. Slowly depress the plunger of the pressure test pump until the pressure gauge

reading stops increasing, and note the highest pressure reading obtained.

4. 4. Release pressure by turning the pressure relief screw counterclockwise. Tighten

the pressure relief screw and repeat step 3 at least twice to make sure the pressure
test reading is repeatable and within acceptable gauge reading limits of the coolant
expansion tank cap.

5. 5. If the pressure test gauge readings are not within the acceptable gauge reading

limits, INSTALL a new coolant expansion tank cap.

Thermostat Test

1. 1. Connect the

Ford approved diagnostic tool

to the data link connector (DLC).

2. 2. Using the Ford approved diagnostic tool datalogger function, SELECT the following

sensors (as applicable to the application):

IAT - intake air temperature (IAT) sensor
ECT - engine coolant temperature (ECT) sensor
CHT - cylinder head temperature (CHT) sensor
LOAD - engine load
VSS - vehicle speed sensor (VSS)
RPM - engine speed
DSRPM - desired engine speed

The IAT sensor output is useful if the engine being tested is cold or after an over-night cold
soak. The ECT sensor or CHT sensor and the IAT sensor should either indicate the same
value or be within 1 to 2 degrees Celsius of each other.

The ECT sensor output is important to display as it indicates the engine warm-up and
opening temperature for the thermostat. It will initially indicate a slightly higher reading
just before the thermostat opens and then drops back before settling to a near flat line
output (see graphic below).

Part Number

Description

Thermostat opens

Thermostat settles into a cyclic open and closure pattern

CAUTION: If the ECT sensor output reaches the 120ºC default line under normal

cooling system pressure, internal damage may be caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM. The test should be stopped and the cause
located and corrected. If the cooling system does not pressurize, the coolant will boil at
100ºC which may also damage the engine. CARRY OUT the Coolant Expansion Tank Cap
Pressure Test Component Test in this section.

If the Ford approved diagnostic tool only allows the ECT sensor to be displayed in volts,
refer to the following table for corresponding Celsius values:

The CHT sensor output is useful to examine the cylinder head temperature rise during the
warm-up cycle and later during the normal light throttle cruise test. This sensor output may
vary between vehicles with manual transmission and vehicles with automatic transmission
and should be used for reference only.

The LOAD display is used for reference as it is necessary to maintain a stable load line
during the test. It is necessary to carry out the test under normal light throttle cruise
driving conditions and average loads, typically 40% to 70% of the load value.

The VSS output is used for reference but can help to identify misfires and sensors which fail
during the warm-up cycle.

The RPM display indicates the engine speed and can be compared with the DSRPM.

The DSRPM is the desired or calculated idle speed which the PCM commands the engine to
reach. If the thermostat opens too early (before the correct opening temperature has been
reached), the engine will not reach this value.

When using the Ford approved diagnostic tool in datalogger mode, the signals recorded
should remain within the DEFAULT values set by the Ford approved diagnostic tool.

WARNING: Make sure that the Ford approved diagnostic tool is placed in the

vehicle so that it does not interfere with the safe operation of the vehicle. Do not
place the Ford approved diagnostic tool in the deployment path of any air bag.
Failure to follow these instructions may result in personal injury.
NOTE: The road test is best carried out with the aid of another technician in the
vehicle to enable the vehicle to be driven safely while the sensor outputs are
monitored within datalogger. If there is only one technician available, the Ford
approved diagnostic tool can be set up (using the record/capture mode camera icon)
before leaving the workshop to record a 16 km (10 mile) test.
NOTE: The results from the test are more conclusive if the engine is cold when the
test is started.

3. Carry out a road test.

REFER to:

Road/Roller Testing

(100-00 General Information, Description and

Operation).

4. 4. Drive the vehicle at a constant throttle opening and set speed until the ECT value

Item

Volts

ºCelsius

1.33

1.02

0.78

0.60

0.46

100

0.35

110

0.27

120

Part Number

Content .. 320 321 322 323 ..