Initial Inspection and Diagnostic Overview
Inspection and Verification
WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may result in serious personal injury.
NOTICE: The cooling system is filled with Motorcraft(R) 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 . Failure to follow these instructions may damage the engine or cooling system.
NOTICE: Use Motorcraft(R) Specialty Orange Engine Coolant. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.
NOTE: During normal vehicle operation, Motorcraft(R) 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.
NOTE: Vehicles have the pressure relief cap on the degas bottle and no radiator cap.
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 (Diagnostic Trouble Codes) retrieved. REFER to Related Module DTC Chart(s) Cooling System
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 (Diagnostic Trouble Codes) 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 Chart - Mechanical / Electrical
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.
1. Inspect the coolant color.
NOTICE: The cooling system is filled with Motorcraft(R) 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 . Failure to follow these instructions may damage the engine or cooling system.
NOTICE: Use Motorcraft(R) Specialty Orange Engine Coolant. Do not mix coolant types. Mixing coolant types degrades the coolant corrosion protection and may damage the engine or cooling system.
NOTE: During normal vehicle operation, Motorcraft(R) 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.
- Discoloration of Motorcraft(R) Specialty Orange Engine Coolant may indicate that incorrect coolant may have been added to the system. Using incorrect (green or yellow) coolant degrades the corrosion protection of Motorcraft(R) Specialty Orange Engine Coolant. Addition of Motorcraft(R) Specialty Green Engine Coolant may cause the color to appear to be a murky green-brown color. The addition of Motorcraft(R) Premium Gold Engine Coolant, however, may not change the color or appearance of the orange colored coolant. Detection of contamination with Motorcraft(R) Premium Gold Engine Coolant is determined by the presence of nitrite. If contamination with Motorcraft(R) Premium Gold Engine Coolant is suspected, test the coolant with 328-00001. Follow the directions in the kit with regard to nitrite testing. If nitrite is present, flush the system and refill with the correct mixture of distilled water and Motorcraft(R) Specialty Orange Engine Coolant. REFER to Cooling System Flushing .
- A darker color 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 engine coolant. REFER to Cooling System Flushing .
- A light to 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 engine 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 Symptom Chart: Engine Performance Symptom Related Diagnostic Procedures. Flush the system and refill with the correct mixture of distilled water and engine 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 Cooling System Pressure Test Cooling System Pressure Test. If engine oil is suspected, the cause of the leak may be internal to the engine. For engine diagnosis, REFER to Symptom Chart: Engine Performance Symptom Related Diagnostic Procedures. Flush the system and refill with the correct mixture of distilled water and engine coolant. REFER to Cooling System Flushing .
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point range with ROB75240. The freezing point should be in the range of -50°C (-58°F) to -26.1°C (-15°F). If the vehicle is driven in cold climates less than -36.7°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.
3. 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 too 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 Symptom Chart.