Lincoln Corsair Manuals

Lincoln Corsair: Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4 / Diagnosis and Testing - Engine Cooling


Special Tool(s)

Coolant/Battery Refractometer
ROB75240 or equivalent
D-Gas Adapter
300-OTC014-R1068 or equivalent
Radiator Tester
014-R1072 or equivalent
UView® Combustion Leak Tester
UVU560000-R

Diagnostic Trouble Code (DTC) Chart

  WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in section 100-00 General Information. Failure to follow this instruction may result in serious personal injury.

NOTICE: Use the correct coolant. Do not mix coolant types. Mixing coolant types may degrade the coolant corrosion protection and may damage the engine or cooling system. For the correct coolant specified for this vehicle, refer to specifications.


REFER to: Health and Safety Precautions (100-00 General Information, Description and Operation).

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


  Diagnostic Trouble Code Chart


Module   DTC Description Action
  PCM P0125:00 Insufficient Coolant Temp For Closed Loop Fuel Control: No Sub Type Information   GO to Pinpoint Test C
  PCM P0128:00 Coolant Thermostat (Coolant Temp Below Thermostat Regulating Temperature): No Sub Type Information   GO to Pinpoint Test C
  PCM P0217:00 Engine Coolant Overtemperature Condition: No Sub Type Information   GO to Pinpoint Test B
  PCM P1299:00 Cylinder Head Overtemperature Protection Active: No Sub Type Information   GO to Pinpoint Test B

Global Customer Symptom Code (GCSC) Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).


Symptom Action
Driver Aid & Information > Warning Indicators/Messages/Chimes > Coolant > Stays On GO to Pinpoint Test A
Driver Aid & Information > Warning Indicators/Messages/Chimes > Coolant > Stays On GO to Pinpoint Test B
Start/Run/Move > Fluids > Coolant > Consumption GO to Pinpoint Test A
Start/Run/Move > Fluids > Coolant > Consumption GO to Pinpoint Test B
Start/Run/Move > Fluids > Coolant > Visible Leak GO to Pinpoint Test A
Start/Run/Move > Fluids > Coolant > Visible Leak GO to Pinpoint Test B

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

Condition Possible Sources Actions
Loss of coolant Refer to the Pinpoint Test   GO to Pinpoint Test A
The engine overheats. Refer to the Pinpoint Test   GO to Pinpoint Test B
The engine does not reach normal operating temperature. Refer to the Pinpoint Test   GO to Pinpoint Test C
The electric cooling fan is inoperative in one or more speeds or does not operate correctly.
  • Wiring
  • Relays
  • Fuses
  • Cooling fan motor
 
The electric cooling fan stays on all the time.
  • Wiring
  • Relays
 

Pinpoint Tests


PINPOINT TEST A: LOSS OF COOLANT

Normal Operation and Fault Conditions

The engine cooling system is a closed system providing for coolant expansion and contraction as well as changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the cooling system.

Possible Sources

  • Coolant hoses or tubes
  • Hose clamps
  • Thermostat O-ring seal or gasket
  • Coolant pump O-ring seal or gasket
  • Thermostat housing (if equipped)
  • Coolant outlet connector (if equipped)
  • Oil cooler (may leak internally or externally) (if equipped)
  • Transmission fluid warmer (may leak internally or externally) (if equipped)
  • Transmission fluid heater coolant control valve
  • EGR cooler (may leak internally or externally) (if equipped)
  • EGR valve (may leak internally or externally) (if equipped)
  • Radiator
  • Pressure relief cap
  • Coolant pump leaking from weep hole
  • Cabin heater coolant pump (if equipped)
  • Heater core
  • Auxiliary heater core (if equipped)
  • Lower intake manifold
  • Engine gaskets (may leak internally or externally)
  • Degas bottle
  • Cylinder block core plugs
  • Cylinder head core plugs
  • Block heater (if equipped)
  • Turbocharger(s) (if equipped)

  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.

A1 CHECK COMPONENTS FOR DAMAGE OR FAILURE
  • Visually inspect the possible sources for obvious signs of physical damage or failure.

Are any concerns present?
Yes REPAIR as needed.
No GO to A2

A2 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE ENGINE COOLING SYSTEM

NOTE: Allow the engine to cool before checking the engine coolant level.

  • Ignition OFF
  • Visually inspect the engine coolant level at the degas bottle and adjust as necessary. Pressure test the engine cooling system. Refer to Component Tests, Cooling System Pressure Test in this section.

Does the engine cooling system leak externally?
Yes REPAIR or INSTALL new components.
No GO to A3

A3 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK
  • Inspect the engine coolant in the degas bottle for signs of engine oil.

Is engine oil evident in the engine coolant?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to A4

A4 CHECK THE ENGINE OIL FOR COOLANT
  • Remove the oil level indicator from the engine.

Is coolant evident in the oil?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to A5

A5 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID
  • Check the engine coolant in the degas bottle for signs of transmission fluid.

Is transmission fluid evident in the engine coolant?
Yes INSTALL a new transmission fluid warmer. REPAIR the transmission as necessary.REFER to: DTC Chart and Pinpoint Tests - 2.3L EcoBoost (199kW/270PS) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to A6

A6 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT
  • Remove the transmission oil leveling plug.
  • Check the transmission fluid for engine coolant.

Is engine coolant evident in the transmission fluid?
Yes INSTALL a new transmission fluid warmer. REPAIR the transmission as necessary.REFER to: DTC Chart and Pinpoint Tests - 2.3L EcoBoost (199kW/270PS) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to A7

A7 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES

NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent.

  • Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases.

Are combustion gases present?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No The cooling system is operational

PINPOINT TEST B: THE ENGINE OVERHEATS

Normal Operation and Fault Conditions

The engine cooling system maintains the engine temperature during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core(s) and turbocharger with coolant. The coolant pump circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit to transfer engine-generated heat to the outside air.

Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at the correct rate, the inability to transfer heat from the engine through the coolant (including low coolant) or an inability to transfer engine-generated heat to the outside air through the radiator.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P0217:00 Engine Coolant Overtemperature Condition: No Sub Type Information Sets in the PCM when an engine overheat condition was sensed by the CHT sensor.
PCM P1299:00 Cylinder Head Overtemperature Protection Active: No Sub Type Information Sets in the PCM when an engine overheat condition was sensed by the CHT sensor.

Possible Sources

  • Low coolant level
  • External engine coolant leak
  • Airlock in system
  • Pressure relief cap installation
  • Restricted airflow through A/C condenser/radiator
  • Internal engine coolant leak
  • Coolant condition/concentration
  • Non-OEM engine enhancement components
  • Electric cooling fan
  • CHT sensor
  • Radiator
  • Thermostat
  • Coolant pump
  • Coolant flow restriction
  • Active grill shutter assembly
B1 CHECK COMPONENTS FOR DAMAGE OR FAILURE
  • Visually inspect the possible sources for obvious signs of physical damage or failure.

Are any concerns present?
Yes REPAIR as needed.
No GO to B2

B2 CHECK FOR PCM (POWERTRAIN CONTROL MODULE) DTCS
  • Ignition ON.
  • Using a scan tool, perform PCM self-test.

Is DTC P0217 and/or P1299 present?
Yes GO to B3
No Actual engine overheating has not been verified. CHECK the engine coolant temperature gauge operation.
REFER to: Instrumentation, Message Center and Warning Chimes - Vehicles With: Head Up Display (HUD) (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
If any other PCM DTCs are retrieved,
REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 2.3L EcoBoost (199kW/270PS), Diagnosis and Testing).

B3 CHECK FOR ACTIVE GRILL SHUTTER DTCS
  • Review the PCM DTCs.

Are any active grill shutter DTCs present?
Yes
REFER to: Active Grille Shutter (501-02 Front End Body Panels, Diagnosis and Testing).
No GO to B4

B4 CHECK FOR AN AIRFLOW OBSTRUCTION AND MISSING AIR DEFLECTORS

NOTE: Verify no vehicle front end damage is present.

  • Check the radiator or A/C condenser for an external obstruction such as leaves or cardboard and verify all air deflectors are present.

Is an airflow obstruction present or air deflectors missing?
Yes REPAIR as necessary.
No GO to B5

B5 CHECK THE ENGINE COOLANT LEVEL AND PRESSURE TEST THE COOLING SYSTEM
  • Ignition OFF.
  • Visually check the engine coolant level in the coolant expansion tank and adjust as necessary. Pressure test the cooling system.

Does the engine cooling system leak externally?
Yes REPAIR or INSTALL new components.
No GO to B6

B6 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK
  • Inspect the engine coolant in the coolant expansion tank for signs of engine oil.

Is engine oil evident in the coolant?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to B7

B7 CHECK THE ENGINE OIL FOR COOLANT
  • Remove the oil level indicator from the engine.

Is coolant evident in the oil?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to B8

B8 CHECK THE ENGINE COOLANT FOR TRANSMISSION FLUID
  • Check the engine coolant in the degas bottle for signs of transmission fluid.

Is transmission fluid evident in the engine coolant?
Yes INSTALL a new transmission fluid warmer. REPAIR the transmission as necessary.REFER to: DTC Chart and Pinpoint Tests - 2.3L EcoBoost (199kW/270PS) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to B9

B9 CHECK THE TRANSMISSION FLUID FOR ENGINE COOLANT
  • Remove the transmission oil leveling plug.
  • Check the transmission fluid for engine coolant.

Is engine coolant evident in the transmission fluid?
Yes INSTALL a new transmission fluid warmer. REPAIR the transmission as necessary.REFER to: DTC Chart and Pinpoint Tests - 2.3L EcoBoost (199kW/270PS) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Diagnosis and Testing).
TEST the system for normal operation.
No GO to B10

B10 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES

NOTE: Use UView® Combustion Leak Tester part number UVU560000-R or equivalent.

  • Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases.

Are combustion gases present?
Yes
REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
No GO to B11

B11 CHECK COOLANT CONDITION
  • Check the coolant for dirt, rust or contamination and check the coolant concentration.

Is the coolant condition OK?
Yes GO to B12
No FLUSH the engine cooling system.
REFER to: Engine Cooling System Flushing (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), General Procedures).

B12 CHECK THE ELECTRIC COOLING FAN OPERATION
  • Start the engine.
  • Place the climate control function selector in the MAX A/C position and the blower motor switch in the HI position.

Did the electric cooling fan operate?
Yes GO to B13
No DIAGNOSE the electric cooling fan operation.

B13 CHECK THE COOLANT PUMP OPERATION
  • Start the engine.
  • Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT position. Feel the heater outlet hose.

Is the heater outlet hose hot?
Yes GO to B14
No INSTALL a new coolant pump.
REFER to: Coolant Pump (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), Removal and Installation).

B14 CHECK THE THERMOSTAT OPERATION

NOTE: This cooling system uses a cold side thermostat. The coolant in the radiator must reach full operating temperature for the thermostat to remain in an open state.

  • Start the engine.
  • Allow the engine to run for 30 minutes. Place the climate control function selector in the MAX HEAT position. Feel the lower radiator hose.

Is the lower radiator hose hot?
Yes CHECK the temperature gauge operation.
REFER to: Instrumentation, Message Center and Warning Chimes - Vehicles With: Head Up Display (HUD) (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
No GO to B15

B15 VISUALLY INSPECT THE THERMOSTAT
  • Carry out the Thermostat Visual Inspection in the Component Tests portion of this section.

Is the thermostat damaged?
Yes INSTALL a new thermostat.
REFER to: Thermostat Housing (303-03 Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4) .
No INSTALL a new thermostat.
REFER to: Thermostat Housing (303-03 Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4) .
If the engine still overheats, INSTALL a new radiator.REFER to: Radiator (303-03B Engine Cooling - 2.3L EcoBoost (199kW/270PS), Removal and Installation).

PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

Normal Operation and Fault Conditions

The engine cooling system maintains engine temperature during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant is sent from the coolant pump through the engine block and cylinder head. A separate circuit from the engine also feeds the core(s) and turbocharger with coolant. The coolant pump circulates the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit in order to transfer engine generated heat to the outside air.

Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant flow through some coolant circuits (radiator, heater core) is more than expected given the conditions. Heat is not allowed to build in the engine because a heat exchanger is removing too much heat, including the radiator, heater core and oil cooler (if equipped). In addition, perceived concerns that the engine does not reach normal operating temperature can be related to a low coolant level or trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.

DTC Fault Trigger Conditions

DTC Description Fault Trigger Condition
PCM P0125:00 Insufficient Coolant Temp For Closed Loop Fuel Control: No Sub Type Information Sets in the PCM when the CHT sensor has not achieved the required temperature level to enter closed loop operating conditions within a specified amount of time after starting the engine.
PCM P0128:00 Coolant Thermostat (Coolant Temp Below Thermostat Regulating Temperature): No Sub Type Information Sets in the PCM when the thermostat monitor has not achieved the required engine operating temperature within a specified amount of time after starting the engine.

Possible Sources

  • Low coolant level
  • Thermostat
  • Temperature gauge
  • CHT

  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.

C1 CHECK COMPONENTS FOR DAMAGE OR FAILURE
  • Visually inspect the possible sources for obvious signs of physical damage or failure.

Were any concerns found?
Yes REPAIR as needed.
No GO to C2

C2 CHECK FOR DTC P0125 OR P0128
  • Using a scan tool, perform the PCM self-test.

Is DTC P0125 or P0128 present?
Yes GO to C3
No The cooling system is operational. If an inoperative temperature gauge is suspected, CHECK the temperature gauge operation.
REFER to: Instrumentation, Message Center and Warning Chimes - Vehicles With: Head Up Display (HUD) (413-01 Instrumentation, Message Center and Warning Chimes, Diagnosis and Testing).
If an inoperative climate control system is suspected, CHECK the climate control system operation.REFER to: Climate Control System (412-00 Climate Control System - General Information, Diagnosis and Testing).
REFER to: Climate Control System (412-00 Climate Control System - General Information, Diagnosis and Testing).
If any other Diagnostic Trouble Codes (DTCs) are retrieved,REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 2.3L EcoBoost (199kW/270PS), Diagnosis and Testing).

C3 CHECK THE COOLANT LEVEL

NOTE: Allow the engine to cool before checking the coolant expansion tank.

  • Visually check the engine coolant level in the coolant expansion tank.

Is the engine coolant level within specification?
Yes INSTALL a new thermostat.
REFER to: Thermostat Housing (303-03 Engine Cooling - 2.0L EcoBoost (177kW/240PS) – MI4) .
CLEAR Diagnostic Trouble Codes (DTCs). If the DTC returns check for correct CHT sensor operation.
No GO to Pinpoint Test A


Component Tests

Cooling System Pressure Test

  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.

NOTE: Vehicles have a pressure relief cap on the degas bottle and no radiator cap.

  1. Turn the engine OFF.
  1. Check the coolant level and adjust as necessary.
  1. Remove the degas bottle cap. Inspect the degas bottle cap and degas bottle for any issues that would cause improper sealing, such as for cross-threading, burrs, damaged o-ring, etc. If any issues are found, or if coolant was expelled through the cap potentially leaving contamination in the gasket, INSTALL a new cap and/or degas bottle.
  1. Attach the Pressure Tester and adaptor (Snap-On TA53 or equivalent), to the degas bottle cap. The cap must hold pressure of 145 kPa +/- 21 kPa (21 PSI +/- 3 PSI). If any issues are found, INSTALL a new cap.
  1. Attach the Pressure Tester and adaptor (Snap-On TA52, AST ASSFZ-47, Redline RDL95-0750 or equivalent) to the degas bottle.
  1. NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the Specifications table in this section or cooling system components may be damaged.

    NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading results.

    To pressurize the engine cooling system, slowly press the plunger of the pressure test pump and increase the pressure to between 124 - 138 kPa (18 - 20 PSI). Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.
  1. If no leaks are found and the pressure drops, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant.
    REFER to: Engine (303-00 Engine System - General Information, Diagnosis and Testing).
  1. If the pressure does not drop remove the cooling system Pressure Tester and adaptor from degas bottle.
  1. Install the degas bottle cap until it contacts the hard stop.

Thermostat

Install a new thermostat only after at least one of the following tests and checks have been carried out:

  • Pinpoint Test B or C
  • Thermostat Visual Inspection

Thermostat Visual Inspection

  1. Remove the thermostat.
  1. Examine the thermostat for signs of damage including:
  • Valve not fully seated (light visible through the valve)
  • Foreign material lodged in the main valve
  • Bent or broken frame or flange
  • Bent or broken spring
  • Wax leaking from wax reservoir or a bulge in the reservoir
  • Any other damage or distortion
  • Worn O-ring seal
  1. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot water or other heat sources. This method is not an accurate means to test the function of the thermostat and may damage the thermostat.

    If damage is found during the inspection, remove any foreign material or broken pieces and install a new thermostat.

Radiator Leak Test, Removed From Vehicle

NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators.

NOTE: Clean the radiator before leak testing to avoid contamination of tank.

  1. Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the Specifications table.

    Diagnosis and Testing - Cooling Fan Control

    Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.REFER to: Diagnostic Methods (100-00 General Information, Description and Operation)...

    Diagnosis and Testing - Engine Temperature

    Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation)...

    Other information:

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