Component Tests and General Diagnostics
Component TestsPressure Test
WARNING: Never remove the radiator cap under any conditions while the engine is operating. Failure to follow these instructions could result in personal injury and/or damage to the cooling system or engine. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first stop. Step back while the pressure is released from the cooling system. When you are certain all the pressure has been released, press down on the radiator cap (with a cloth), turn and remove.
1. Remove the radiator cap. Fill the radiator as needed. Fit the pressure tester to radiator neck using an aftermarket adapter.
2. CAUTION: Do not pressurize the cooling system beyond 102 kPa (14.9 psi).
Pump the cooling system to a maximum of 102 kPa (14.9 psi) and hold for two minutes. If the pressure drops within this time, inspect for leaks and repair as required.
Cap-Radiator
1. Inspect the radiator cap and seals for damage or deterioration. Install a new radiator cap if necessary.
2. Fit radiator cap to Radiator/Heater Core Pressure Tester Kit using the aftermarket adapter.
3. NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading will result.
Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release pressure and repeat test. Install a new radiator cap if the pressure is not 99.3 - 121.4 kPa (14.4 - 17.6 psi).
Thermostat
NOTE: Overheating or failure to reach normal operating temperature can indicate incorrect thermostat operation. Inspection and temperature-testing of the water thermostat will verify its condition.
NOTE: Insufficient heat and failure of the engine to reach operating temperature can indicate low temperature leakage of the water thermostat. Cool the water thermostat to room temperature for this inspection.
1. Remove the water thermostat.
2. Hold the thermostat against a lighted background and inspect for light between the valve and valve seat. If light is visible install a new thermostat.
Thermostat-Mechanical Test
1. Suspend the water thermostat and an accurate thermometer in a suitable container filled with water. Do not allow the water thermostat and the thermometer to touch the bottom of the container.
2. Heat the water until boiling while observing the thermometer temperature.
3. NOTE: "Fully open" means the water thermostat valve lifts a distance of 5.8 mm (0.23 inch) or more off of the valve seat.
The water thermostat should begin to open at:
^ 87° - 90°C (188° - 195°F) -2.0L SPI
^ 90° - 94°C (194° - 201°F) -2.0L Zetec
4. The water thermostat should be fully open at:
^ °100°C (212°F) -2.0L SPI
^ 106°C (223°F) -2.0L Zetec
5. Install a new water thermostat if it does not operate as specified.
Radiator Leak Test, Removed from Vehicle
CAUTION: 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: Always install plugs in the oil cooler fittings before leak-testing or cleaning any radiator.
NOTE: Clean the radiator before leak-testing to avoid contamination of tank.
1. Leak-test the radiator in clean water with 138 kPa (20 psi) air pressure.
Thermostat-Electrical Test
CAUTION: Always vent the exhaust to the outside when performing this test.
NOTE: This procedure will diagnose only cooling systems that may not be reaching normal operating temperature. It will not diagnose a water thermostat that causes an engine overheat condition.
NOTE: Disconnecting the powertrain control module to attach a breakout box or an EEC IV monitor will erase the adaptive learning from memory and may hide a drive concern temporarily until the adaptive learning is re-learned.
NOTE: This procedure is most accurate if performed indoors at less than 100°F (38°C) ambient temperature. This test may be performed with or without the hood open and with the engine warm or cold.
1. Check the coolant level in the radiator and radiator coolant recovery reservoir.
2. With the ignition switch in the OFF position, proceed as follows:
1 Remove the engine coolant temperature (ECT) sensor harness connector.
2 Attach Rotunda Service Coolant Temperature Monitor Harness as a jumper between the PCM and the ECT.
3 Attach Rotunda 73 Digital Multimeter to the thermostat monitor harness. Voltage values (0-5v dc) may now be monitored while the sensor retains its connection to the wiring harness.
NOTE: A scan tool may be used to monitor the ECT on vehicles equipped with Data Communications Link (DCL).
3. Vehicles equipped with electric engine cooling fan(s) must have a cooling fan running during this test (high or low speed may be used). Two methods may be used to turn the fan(s) on:
1 Disconnect the A/C compressor clutch power supply and turn the climate control to A/C ON.
2 Disconnect the power supply to the cooling fan and supply 12 volts direct to the fan connector from the battery.
NOTE: A ground may be required for some applications.
4. Place transmission in PARK or NEUTRAL.
NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause incorrect diagnosis.
5. Start the engine and allow to idle throughout this test:
1 Allow engine to run for two minutes, then record ECT voltage.
2 From now on, record ECT voltage every 60 seconds.
3 When the ECT voltage trend changes direction or changes only slightly (0.03 volt or less) from the previous reading, record this as the thermostat opening voltage.
4 Use the Voltage and Corresponding Temperature Chart shown below to obtain actual coolant temperatures.
Voltages And Corresponding Temperatures:
Voltages And Corresponding Temperatures
6. If the opening voltage is GREATER than 0.75 volt (less than 180°F/ 82°C), install a new water thermostat.
7. If the thermostat opening voltage is LESS than 0.75 volt (greater than 180°F/ 82°C), the water thermostat is good and should NOT be replaced.