Ford Galaxy / Ford S-MAX. Manual - part 352

Engine Cooling - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-
TDCi (103kW/140PS) - DW - Radiator

S-MAX/Galaxy 2006.5 (02/2006-)

Removal and Installation

General Equipment

Removal

NOTE: Removal steps in this procedure may contain installation details.

Cable ties

1. Drain the cooling system.

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).

2. Remove the cooling fan motor and shroud.

Refer to:

Cooling Fan Motor and Shroud

(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).

3. Remove the charge air cooler (if equipped).

Refer to:

Charge Air Cooler

(303-12E Intake Air

Distribution and Filtering - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW/2.0L Duratorq-TDCi
(118kW/160PS) - DW, Emission Requirements:
Stage IV/Stage V, Removal and Installation).
Refer to:

Charge Air Cooler

(303-12E Intake Air

4. Secure the air conditioning (A/C) condenser to

the front panel.

General Equipment:

Cable ties

Installation

NOTE: This step requires the aid of another
technician.
NOTE: Radiator insulators are to be reused
unless damaged.

Remove the cable ties.

NOTE: Make sure that no components catch
when installing the radiator.

To install, reverse the removal procedure.

Engine Cooling - 2.2L Duratorq-TDCi
(129kW/175PS) - DW - Engine Cooling

S-MAX/Galaxy 2006.5 (02/2006-)

Diagnosis and Testing

Special Tool(s)

General Equipment

Inspection and Verification

1. 1. Verify the customer concern.

2. 2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

3. 3. If an obvious cause for an observed or reported concern is found, correct the cause

(if possible) before proceeding to the next step

4. 4. If the cause is not visually evident, verify the symptom and refer to the Symptom

Chart.

Symptom Chart

Pressure Tester, Cooling System

303-396 (24-001 A)

Adaptor for 303-396

303-396-09

Ford approved diagnostic tool

Mechanical

Electrical

Coolant leaks
Gaskets/seals
Core plug(s)
Hose(s)/hose joints
Coolant expansion tank cap and seal(s)
Coolant expansion tank
Radiator
Coolant pump
Thermostat
Heater core
Exhaust gas recirculation (EGR) cooler

Fuse(s)
Wiring harness
Electrical connector(s)
Engine coolant temperature (ECT) sensor
Cooling fan motor
Cooling fan module
Powertrain control module (PCM)

Symptom

Possible Sources

Action

Loss of coolant

Coolant

expansion tank
cap or seal(s).

CHECK the coolant expansion tank cap for tightness

and damage. INSTALL a new coolant expansion cap
as necessary.

Cooling system.

INSPECT the cooling system for leaks. CARRY OUT

the Pressure Test Component Test in this section.
INSTALL new component(s) as necessary.

Engine.

INSPECT the engine, cylinder head, cylinder block

and cylinder head gasket.

REFER to:

Cylinder Head

(303-01F Engine - 2.0L

Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).

The engine
overheats (signs of
coolant boiling)

Air in cooling

system.

BLEED the cooling system.

REFER to:

Cooling System Draining, Filling and

Bleeding

(303-03E Engine Cooling - 2.0L Duratorq-

TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, General Procedures).

Cooling system

does not hold
pressure.

CHECK the coolant expansion tank cap for tightness

and damage. INSTALL a new coolant expansion
tank cap as necessary.

INSPECT the engine, cylinder head, cylinder block

and cylinder head gasket.
REFER to:

Cylinder Head

(303-01F Engine - 2.0L

Duratorq-TDCi (85kW/115PS) - DW/2.0L Duratorq-
TDCi (100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, Emission Requirements:
Stage IV, Removal and Installation).

Coolant

level/condition.

CHECK the coolant level. REFILL the cooling system

as necessary.
REFER to:

Cooling System Draining, Filling and

Bleeding

(303-03E Engine Cooling - 2.0L Duratorq-

TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, General Procedures).

CHECK the coolant condition and concentration. If

the coolant is contaminated or the concentration is
below specifications, drain and refill with new
coolant.
REFER to:

Cooling System Draining, Filling and

Bleeding

(303-03E Engine Cooling - 2.0L Duratorq-

TDCi (85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, General Procedures).

Radiator grille.

INSPECT the radiator grille for air

restrictions/damage. REPAIR or INSTALL new parts
as necessary.

Cooling fan

motor.

CHECK the operation of the cooling fan. REFER to

the Ford approved diagnostic tool.

Thermostat.

CARRY OUT the Thermostat Test Component Test

in this section. INSTALL a new thermostat as
necessary.
REFER to:

Thermostat

(303-03E Engine Cooling -

2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) - DW, Removal and
Installation).

Coolant pump.

REMOVE AND INSPECT the coolant pump/impeller.

INSTALL a new coolant pump/coolant pump gasket
as necessary.
REFER to:

Coolant Pump

(303-03E Engine Cooling -

2.0L Duratorq-TDCi (85kW/115PS) - DW/2.0L
Duratorq-TDCi (100kW/136PS) - DW/2.0L
Duratorq-TDCi (103kW/140PS) - DW, Removal and
Installation).

Engine.

INSPECT the engine, cylinder head, cylinder block

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