Inspection and Verification

• 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  for DTC descriptions.

• 5.
  
  
  NOTE: Take note of any coolant odor or steam coming from cooling system components.

  If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved, verify the customers concern by operating the engine to duplicate the condition.

• 6.
  
  
  NOTE: For the coolant flow diagram, refer to Engine Cooling .

  Visually inspect for obvious signs of any mechanical or electrical concerns damage.

Visual Inspection Chart 

• 7.
  
  If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test the system for normal operation.

• 8.
  
  
  NOTE: The engine cooling system is filled with Motorcraft ® Orange Antifreeze/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 . Failure to follow these instructions may damage the engine or cooling system.
  NOTE: Use Motorcraft ® Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.
  NOTE: Do not use stop-leak style pellets/products 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: During normal vehicle operation, Motorcraft ® Orange Antifreeze/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.

  Inspect the coolant condition in the following sequence:

  • 1.
    
    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 ® Orange Antifreeze/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 nitrite testing directions in the kit to determine if nitrite is present in the system. If nitrite is present, flush the system and refill with the correct mixture of distilled water and Motorcraft ® Orange Antifreeze/Coolant. Refer to Cooling System Flushing .
    • 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 ® Orange Antifreeze/Coolant. Refer to Cooling System Flushing .
    • A light or reddish brown color indicates that rust may be present in the cooling system. Flush the system and refill with the correct mixture of distilled water and Motorcraft ® Orange Antifreeze/Coolant. Refer to Cooling System Flushing .
    • An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For engine diagnosis, refer to Engine System - General Information . Flush the cooling system and refill with the correct mixture of distilled water and Motorcraft ® Orange Antifreeze/Coolant. Refer to Cooling System Flushing .
    • A milky brown color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to the Component Tests . If engine oil is suspected, the cause of the leak may be internal to the engine. For engine diagnosis, refer to Engine System - General Information . Flush the cooling system and refill with the correct mixture of distilled water and Motorcraft ® Orange Antifreeze/Coolant. Refer to Cooling System Flushing .
    • NOTE: During normal vehicle operation, Motorcraft ® Orange Antifreeze/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. Transmission fluid will float on top of the coolant or turn the coolant a milky red color.

      For 2.0L GTDI, a red sheen on top of the coolant or a milky red color may indicate that transmission fluid is entering the cooling system. Pressure test the cooling system. Refer to the Component Tests . If transmission fluid is entering the cooling system install a new radiator. Refer to Radiator - 2.0L GTDI . Install a new transmission fluid cooler/warmer. Refer to Transmission Cooling 6F35 . Repair the transmission. Refer to Automatic Transmission 6F35 .

  • 2.
    
    If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the Coolant/Battery Refractometer. The coolant concentration should be maintained within 48% to 50%, which equates to a freeze point between -34 °C (-30 °F) and -37 °C (-34 °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 48/52 to 50/50 (freeze protection -34 °C (-30 °F) and -37 °C (-34 °F)) 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.

  • 3.
    
    Adjust coolant range and level if necessary:
    • If coolant is low, add Motorcraft ® Orange Antifreeze/Coolant Prediluted.
    • If the engine coolant tests too weak, remove some of the engine coolant and add Motorcraft ® Orange Antifreeze/Coolant Concentrated 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.
  
  
  NOTE: Make sure to use the latest scan tool software release.

  If the cause is not visually evident, connect the scan tool to the DLC.

• 11.
  
  
  NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the VCM.

  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 , No Power To The Scan Tool, to diagnose no power to the VCM.

• 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 , The PCM Does Not Respond To The Scan Tool, 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 .
  • If the network test passes, retrieve and record the CMDTCs.

• 14.
  
  Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.

• 15.
  
  If the DTCs retrieved are related to the concern, GO to the PCM DTC Chart . For all other PCM DTCs, refer to Electronic Engine Controls .

• 16.
  
  If no DTCs related to the concern are retrieved, GO to Symptom Chart .