Engine Cooling I.

3L Duratec-8V -
(Rocam)llI25L Duratec-16V (Sigma)llm4L
303-03A-1 Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma) 303-03A-I

SECTION 303-03A Engine Cooling - 1.3L Duratec-8V

i

(Rocam)/l.25L Duratec-16V (Sigma)/l.4L Duratec-16V

(Sigma)/l .6L Duratec-16V (Sigma)
VEHICLE APPLICATION:2006.0 Fiesta
CONTENTS PAGE

SPECIFICATIONS
Specifications............................................................................................................... 303-03A-2

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DESCRIPTION AND OPERATION
Engine Cooling - 1.4L Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma)......................... 303-03A-4
Overview............................................................................................................................. 303-03A-4
Components....................................................................................................................... 303-03A-5

DIAGNOSIS AND TESTING

Engine Cooling................................................................................................................... 303-03A-8
Inspection and Verification.............................................................................................. 303-03A-8
j Symptom Chart................................................................................................................... 303-03A-8
Component Tests.. .............................................................................................................. 303-03A-4 6

GENERAL PROCEDURES
Cooling System Draining, Filling and Bleeding - I.3L Duratec-8V
(Rocam)/l.25L Duratec-16V (Sigma)/l.4L Duratec-16V (Sigma)/l.GL
Duratec-16V (Sigma)........................................................................... ........ (24 122 0) 303-03A-19
Draining..............................................................................................................................303-03A-19
Filling and Bleeding...................................................................................................... 303-03A-19

REMOVAL AND INSTALLATION

Water Pump - 1.25L Duratec-I 6V (Sigma)/l.4L Duratec-I 6V (Sigma)ll .6L
Duratec-16V (Sigma).................................................................................... (24 404 0) 303-03A-21
Thermostat - 1.25L Duratec-16V (Sigma)/l.4L Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma).................................................................................... (24 454 0) 303-03A-24
Radiator.......................................................................................................... (24 254 0) 303-03A-26
 Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)ll .6L Duratec-16V (Sigma)
SPECIFICATIONS
Lubricants, Fluids, Sealers and Adhesives
Description
I Specificatio 1(,
Motorcraft Super Plus 2000 antifreeze

Antifreeze -All vehicles used in climates where daytime ambient air temperature does not regularly
exceed +46OC (+I15°F)
Specific gravity Approximate Remains fluid to Solidifies at
(providing no other percentage of anti-
additive is in the freeze (by volume)
coolant)

-
Antifreeze Vehicles with 1.25U1.4U1 .6L engine used in climates where daytime ambient air

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temperature regularly exceeds +46OC (+I15OF)
Specific gravity (providing no other additive is Approximate percentage of antifreeze (by
in the coolant) volume)

Cooling System Refill Capacities

Description Liters

1 Cooling system, including heater system and coolant expansion tank (all except vehicles
with diesel engine)

Cooling System Pressure Specification

Description Pressure kpa (psi)
I Radiator pressure test I 138 (20) I
I Coolant expansion tank cap release pressure I 120 to 150 (17-21) I
-
Torque Specifications vehicles with 1.25U1.4U1 .6L engine
Description Nm Ib-ft Ib-in
I Radiator retaining nut I 10 I - I 89 1
Thermostat housing retaining bolts 10 - 89
Water pump retaining bolts 10 - 89
w r p u m p pulley retaining bolts I 24 I 18 I - I
I Generator retaining bolts I 45 I 33 I - I
I Generator electrical connector retaining nut I 8 I - I 71 I
I Timing belt lower cover retaining bolts I 9 I - I 80 I
Torque Specifications - vehicles with I.3L engine 1

I Description I Nm I Ib-ft I Ib-in I,.

I Radiator retaining nut I 10 I - I 89 1 '\..
Water pump retaining bolts 10 - 89
I Water pump pulley retaining bolts I 12 I 9 I - I
2006.0 Fiesta 1212006 Gl46257en
 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)ll.GL Duratec-16V (Sigma)
SPECIFICATIONS
Description Nm Ib-ft Ib-in
Thermostat housing retaining bolts 10 - 89

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2006.0 Fiesta 1212006 G I 46257en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma)
DESCRIPTION AND OPERATION

Engine Cooling - 1.4L Duratec-I 6V (Sigma)/l .6L Duratec-16V

(Sigma)
Overview

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Description Item Description

4 Heater heat exchanger I "

5 Thermostat housing (\
6 Coolant expansion tank
7 Radiator

2006.0 Fiesta 1212006 GI 79022en

 Engine Cooling -
I.3L DuratecdV
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)ll .6L Duratec-16V (Sigma)
DESCRIPTION AND OPERATION
Components

Coolant pump

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Item Description It is driven through a pulley b;the accessory drive

belt.
1 Coolant pump
The gasket for the coolant pump must not be
2 Coolant pump gasket reused.
I

The coolant pump is secured to the engine block

at the timing gear end.

2006.0 Fiesta 1212006 GI 79022en

 -
Engine Cooling I.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
303-03A-6 Duratec-I6V (Sigma)/l .6L Duratec-I6V (Sigma) 303-03A-6
DESCRIPTION AND OPERATION
Thermostat and thermostat housing

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Item Description The thermostat and thermostat housing are located
I I
1 Thermostat housing on the side of the engine block.
2 Thermostat When installing the thermostat, make sure that the
venting pin is at the top.
3 Venting pin

- - -- --- - -- - -

2006.0 Fiesta 1212006 GI 79022en

 Enaine Cooling - 1.3L Duratec-8V
(~ocah)ll.25L~Cratec-1 6~ (Sigma)ll.4L
303-03A-7 Duratec-16V (Sigma)ll.6L Duratec-16V (Sigma) 303-03A-7
DESCRIPTION AND OPERATION
Water outlet housing

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Item Description
1 Gasket
2 Water outlet housing
Coolant Temperature (ECT)
sensor
The water outlet housing is located on the cylinder
head nearest the transmission.
Among other things, it is used to mount the
Electronic Ignition (El) coil.
In addition, the ECT sensor is located in the
housing.

2006.0 Fiesta 1212006 G I 79022en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
303-03A-8 Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma) 303-03A-8
DIAGNOSIS AND TESTING

Engine Cooling
Special Tool(~) Visual Inspection Chart i,
Pressure Tester, Cooling
System
I Mechanical I Electrical I
303-396 (24-001 A) - Coolant leak(s) - Fuse(s)
- Coolant level - Relay(s)
- Air in system - Wiring harness
- Gasketslseals - Electrical
- Hose(s)lhose joints connector(s)
- Coolant expansion - Cooling fan motor
tank cap and seal - Engine coolant
- Coolant expansion temperature (ECT)
tank sensor
- Radiator - Cylinder head

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- Water pump temperature (CHT)
sensor
- Thermostat
- Powertrain control
General Equipment - Thermostat housing module (PCM)
I
Worldwide Diagnostic System (WDS) I - Accessory drive belt

3. If an obvious cause for an observed or reported

Inspection and Verification concern is found, correct the cause (if possible)
before proceeding to the next step.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical
4. If the cause is not visually evident, verify the (
symptom and refer to the Symptom Chart.
or electrical damage.

Symptom Chart
Symptom Chart
Svmptom Possible Sources Action
Loss of coolant INSPECT the hoses and hose
joints. INSTALL a new hose(s)
as necessary.
Radiator. INSPECTthe radiator for leaks.
CARRY OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)1ln4L
Duratec-16V (Sigma)ll .6L
Duratec-I6V (Sigma),
Removal and Installation).

2006.0 Fiesta 1212006 GI 46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-9 Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma) 303-03A-9
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Water pump. INSPECT the water pump for
leaks. CARRY OUT the Pres-
sure Test Component Test in
this section. INSTALL a new
water pump or water pump
gasket as necessary.
REFER to: Water Pump - I.3L
Duratec-8V (Rocam) (303-03
Engine Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma),
Removal and Installation)
IWater Pump - 1.25L Duratec-

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16V (Sigma)/l.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V
(Sigma), Removal and
Installation).
Thermostat housing. INSPECT the thermostat
housing for leaks. CARRY OUT
the Pressure Test Component
Test in this section. INSTALL
a new thermostat housing or
thermostat housing gasket as
necessary.
REFER to: Thermostat - 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling - I.3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V (Sigma)ll.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)/l.4L Duratec-16V
(Sigma)/l .6L Duratec-16V
(Sigma), Removal and
Installation).

2006.0 Fiesta 1212006 Gl46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma)
DIAGNOSIS AND TESTING
Symptom Possible Sources
Coolant expansion tank cap or
seal.
Coolant expansion tank.
Heater core.
Engine.
2006.0 Fiesta 1212006
Action
CHECK the coolant expansion
tank cap for tightness. If OK, I
CARRY OUT the Coolant
Expansion Tank Cap Pressure
Test Component Test in this
section.
INSPECT the seal face on the
coolant expansion tank for
damage. INSTALL a new
coolant expansion tank as
necessary.
CHECK the heater core for
leaks.
INSPECT the engine, cylinder
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head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - I.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma), In-vehicle
Repair).
GI 46258en
 Engine Cooling -
1.3L Duratec-8V
(Rocam)llI25L Duratec-16V (Sigma)llI4L
303-03A-I I Duratec-16V (Sigma)/lI6L Duratec-I6V (Sigma) 303-03A-1I
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
The engine overheats (signs of Cooling system does not hold CARRY OUT the Coolant
coolant boiling) pressure. Expansion Tank Cap Test
Component Test in this section.
INSPECT the coolant expan-
sion tank for damage. INSTALL
a new coolant expansion tank
as necessary.
INSPECT the water pump or
water pump gasket for damage.
INSTALL a new water pump or
water pump gasket as neces-
sary.
REFER to: Water Pump - 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling - 1.3L

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Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-
16V (Sigma)ll.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V
(Sigma), Removal and
Installation).
INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l .6L Duratec-
16V (Sigma), In-vehicle
Repair).
Radiator. INSPECT the radiator for
blockage or damage. CARRY
OUT the Pressure Test
Component Test in this section.
INSTALL a new radiator as
necessary.
REFER to: Radiator (303-03
Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-I 6V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation).

2006.0 Fiesta 1212006 G I 46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)llI4L
303-03A-I 2 Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma) 303-03A-12
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Air in system. BLEED the cooling system.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)/l.4L Duratec-I 6V
(Sigma)/l .6L Duratec-16V
(Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)/l.4L Duratec-16V
(Sigma)/l .6L Duratec-16V
(Sigma), General Proced-
ures).
Coolant expansion tank cap or CHECK the coolant expansion

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seal. tank cap for tightness. If OK,
CARRY OUT the Coolant
Expansion Tank Cap Pressure
Test Component Test in this
section.
Coolant expansion tank. INSPECT the seal face on the
coolant expansion tank for
damage. INSTALL a new
coolant expansion tank as
necessary.

2006.0 Fiesta 1212006 Gl46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
303-03A-I 3 Duratec-16V (Sigma)ll.GL Duratec-16V (Sigma) 303-03A-I 3
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Coolant levellcondition. CHECK the coolant level.
REFILL the cooling system as
necessary.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V
(Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V
(Sigma), General Proced-

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ures).
CHECK the coolant condition.
If the coolant is in poor condi-
tion drain and refill with new
coolant.
REFER to: Cooling System
Draining, Filling and Bleeding
- 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V
(Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)/l.6L Duratec-16V
(Sigma), General Proced-
ures).
Coolant concentration. REFER to: Specifications (303-
03 Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)/l .6L
Duratec-16V (Sigma),
Specifications).
Radiator grille. INSPECT the radiator grille for
air restrictions or damage.
REPAIR or INSTALL new parts
as necessary.

2006.0 Fiesta 1212006 GI 46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-16V (Sigma)llm4L
303-03A-I 4 Duratec-I6V (Sigma)ll.6L Duratec-16V (Sigma) 303-03A-I 4
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Water pump. CARRY OUT the Pressure Te
Component Test in this section.
INSPECT the water pump for
leaks. INSTALL a new water
pump or water pump gasket as
necessary.
REFER to: Water Pump - I.3L
Duratec-8V (Rocam) (303-03
Engine Cooling - I.3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L
Duratec-I 6V (Sigma),
Removal and Installation)
/ Water Pump - 1.25L Duratec-

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16V (Sigma)/l.4L Duratec-
16V (Sigma)/l.GL Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)/l.4L Duratec-16V
(Sigma)/l.GL Duratec-16V
(Sigma), Removal and
Installation).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary.
REFER to: Thermostat - 1.3L
Duratec-8V (Rocam) (303-03
Engine Cooling - 1.3L
Duratec-8V (Rocam)/l.25L
Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l.GL
Duratec-16V (Sigma),
Removal and Installation)
/ Thermostat - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l.GL Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V
(Sigma)/l.4L Duratec-16V
(Sigma)ll .6L Duratec-16V
(Sigma), Removal and
Installation).

'
Accessory drive belt CHECK the accessory drive
belt for correct operation. ,'

REFER to: Accessory Drive

(303-05 Accessory Drive,
Diagnosis and Testing).

2006.0 Fiesta 1212006 GI 46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-16V (Sigma)llI4L
303-03A-I 5 Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma) 303-0344-15
DIAGNOSIS AND TESTING
Symptom Possible Sources Action
Cooling fan motor. CHECK the operation of the
cooling fan motor. REFER to
WDS.
Engine. INSPECT the engine, cylinder
head, cylinder block and
cylinder head gasket.
REFER to: Cylinder Head (303-
01 Engine - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)/l.GL Duratec-
16V (Sigma), In-vehicle
Repair).

, The engine does not reach

normal operating temperature.
ECT sensor.
I CHECK the ECT sensor.
REFER to WDS.

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Temperature gauge. CHECK the instrument cluster
engine temperature gauge.
REFER to: lnstrument Cluster
- Vehicles Built Up To:
1012005 (413-01 lnstrument
Cluster, Diagnosis and
Testing)
Ilnstrument Cluster - Vehicles
Built From: 1012005 (413-01
lnstrument Cluster, Diagnosis
and Testing).
Thermostat. CARRY OUT the Thermostat
Test Component Test in this
section. INSTALL a new ther-
mostat as necessary.
REFER to: Thermostat - I.3L
Duratec-8V (Rocam) (303-03
Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)ll .6L
Duratec-16V (Sigma),
Removal and Installation)
IThermostat - 1.25L Duratec-
16V (Sigma)/l.4L Duratec-
16V (Sigma)ll .6L Duratec-
16V (Sigma) (303-03 Engine
Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V
(Sigma)ll.4L Duratec-16V
(Sigma)/l .6L Duratec-I 6V
(Sigma), Removal and
Installation).

2006.0 Fiesta 1212oo6 G I 46258en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)ll.4L
303-03A-16 Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma)
DIAGNOSIS AND TESTING
Component Tests
Pressure Test
A WARNING:When releasing the system
pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility
of coolant scalding, Failure to follow this
instruction may result in personal injury.
1. Remove the coolant expansion tank cap.
2. Install the special tools to the coolant expansion
tank.
3. Pressurize the system to the coolant expansion
tank cap release pressure.
REFER to: Specifications (303-03 Engine
Cooling - 1.3L Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L Duratec-16V
(Sigma)/l .6L Duratec-16V (Sigma),
Specifications).
4. Observe the cooling system pressure tester
gauge reading for approximately two minutes.
The pressure should not drop during this time.
If the system holds pressure, proceed to step
6. If the system does not hold pressure, check
it thoroughly for coolant leaks.
5. Check the engine for coolant leaks. Drain the
cooling system, repair any coolant leaks found
and fill and bleed the cooling system as
necessary.
REFER to: Cooling System Draining, Filling and
Bleeding - 1.3L Duratec-8V (Rocam)/l.25L
Duratec-I 6V (Sigma)/l.4L Duratec-16V
(Sigma)/l .6L Duratec-16V (Sigma) (303-03
Engine Cooling - 1.3L Duratec-8V
(Rocam)/l.25L Duratec-16V (Sigma)/l.4L
Duratec-16V (Sigma)/l .6L Duratec-16V
(Sigma), General Procedures).
6. Recheck the system by repeating steps 3 and
4 at least twice.
Radiator Leak Test, Removed From Vehicle
A CAUTI0N:Radiator internal pressure must
not exceed 130 kpa (20 psi) or damage may
result.
2006.0 Fiesta 1212006
303-03A-16
Clean the radiator thoroughly before leak testing
it, to prevent contamination of the water in the test
tank. Leak test the radiator in clean water with 138(
kpa (20 psi) air pressure. Check it thoroughly for
air leaks. INSTALL a new radiator if necessary.
REFER to: Radiator (303-03 Engine Cooling - 1.3L
Duratec-8V (Rocam)/l.25L Duratec-I 6V
(Sigma)/l.4L Duratec-I 6V (Sigma)ll .6L
Duratec-I6V (Sigma), Removal and Installation).
Coolant Expansion Tank Cap Pressure Test
A WARNING:When releasing the system
pressure, cover the expansion tank cap
with a thick cloth to prevent the possibility
of coolant scalding, Failure to follow this
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instruction may result in personal injury.
1. Remove the coolant expansion tank cap.
2. Use water to clean the area of the rubber seal
and pressure relief valve. Install the pressure
tester and adapter and immerse the coolant
expansion tank cap in water .
N0TE:lf the plunger of the pump is depressed too
quickly, an erroneous pressure reading will result.
l-
3. Slowly depress the plunger of the pressure test \
pump until the pressure gauge reading stops
increasing, and note the highest pressure
reading obtained.
4. Release pressure by turning the pressure relief
screw counterclockwise. Tighten the pressure
relief screw and repeat step 3 at least twice to
make sure the pressure test reading is
repeatable and within acceptable gauge reading
limits of the coolant expansion tank cap.
5. If the pressure test gauge readings are not
within the acceptable gauge reading limits,
INSTALL a new coolant expansion tank cap.
Thermostat Test
1. Connect the WDS to the data link connector
(DLC).
2. Using the WDS datalogger function, SELECT
the following sensors (as applicable to the
application):
IAT - intake air temperature (IAT) sensor
ECT - engine coolant temperature (ECT) sensort
CHT - cylinder head temperature (CHT) sensori\
LOAD - engine load
VSS - vehicle speed sensor (VSS)
G I 46258en
 Engine Cooling - I.3L Duratec-8V
(Rocam)llm25LDuratec-16V (Sigma)ll.4L
303-03A-17 Duratec-16V (Sigma)/lm6L
Duratec-16V (Sigma)
DIAGNOSIS AND TESTING
RPM - engine speed
i
DSRPM - desired engine speed
The IAT sensor output is useful if the engine being
tested is cold or after an over-night cold soak. The
ECT sensor or CHT sensor and the IAT sensor
should either indicate the same value or be within
1 to 2 degrees Celsius of each other.
The ECT sensor output is important to display as
it indicates the engine warm-up and opening
temperature for the thermostat. It will initially
indicate a slightly higher reading just before the
thermostat opens and then drops back before
settling to a near flat line output (see graphic
below).
Item Description
I I
A Thermostat opens
IA I B Thermostat settles into a cyclic open and
closure pattern
CAUTI0N:lf the ECT sensor output reaches
the 120°C default line under normal cooling
system pressure, internal damage may be
caused to the engine and a diagnostic
trouble code (DTC) will be set in the PCM.
The test should be stopped and the cause
located and corrected. If the cooling
system does not pressurize, the coolant
will boil at 100°C which may also damage
the engine. CARRY OUT the Coolant
Expansion Tank Cap Pressure Test
Component Test in this section.
If the WDS only allows the ECT sensor to be
displayed in volts, refer to the following table for
corresponding Celsius values:
Volts OCelsius
2006.0 Fiesta 1212006
303-03A-17
Volts OCelsius
0.78 80
0.60 90
0.46 100
0.35 110
0.27 120
The CHT sensor output is useful to examine the
cylinder head temperature rise during the warm-up
cycle and later during the normal light throttle cruise
test. This sensor output may vary between vehicles
with manual transmission and vehicles with
automatic transmission and should be used for
reference only.
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The LOAD display is used for reference as it is
necessary to maintain a stable load line during the
test. It is necessary to carry out the test under
normal light throttle cruise driving conditions and
average loads, typically 40% to 70% of the load
value.
The VSS output is used for reference but can help
to identify misfires and sensors which fail during
the warm-up cycle.
The RPM display indicates the engine speed and
can be compared with the DSRPM.
I The DSRPM is the desired or calculated idle speed
which the PCM commands the engine to reach. If
the thermostat opens too early (before the correct
opening temperature has been reached), the
engine will not reach this value.
When using the WDS in data logger mode, the
signals recorded should remain within the
DEFAULT values set by the WDS.
3mA W A R N I N G : M ~sure
~ ~ that the WDS is
placed in the vehicle so that it does not
interfere with the safe operation of the
vehicle. Do not place the WDS in the
deployment path of any air bag. Failure to
follow these instructions may result in
personal injury.
N0TE:The road test is best carried out with the
aid of another technician in the vehicle to enable
the vehicle to be driven safely while the sensor
outputs are monitored within datalogger. If there
is only one technician available, the WDS can be
set up (using the recordlcapture mode camera
icon) before leaving the workshop to record a 16
km (10 mile) test.
G I 46258en
 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll125LDuratec-16V (Sigma)ll14L
3-03A-18 Duratec-I6V (Sigma)ll.GL Duratec-16V (Sigma)
DIAGNOSIS AND TESTING
N0TE:The results from the test are more
conclusive if the engine is cold when the test is
started.
Carry out a road test.
REFER to: RoadlRoller Testing (100-00 General
Information, Description and Operation).
4. Drive the vehicle at a constant throttle opening
and set speed until the ECT value settles into
a shallow rise and fall signal, close to a straight
line. This indicates that the thermostat is
functioning correctly.
N0TE:Some thermostats indicate the
temperature(s) in Celsius and Fahrenheit.
The graphic below shows the location and an
example of the opening temperature (88OC) and
fully open temperature (102OC) of a thermostat.
The graphic below shows an alternative method
used to show the opening temperature (88OC) and
fully open temperature (112OC) of a thermostat.
Item Description
I 1
A Opening temperature
I B I Fully open temperature
NOTE:Generally, most thermostats maintain a
coolant temperature between 88OC (190°F) and
92OC (198OF) although dual stage electric
2006.0 Fiesta 1212006
303-03A-18
thermostats may increase the coolant temperature
up to 1OO°C (212OF) under light engine load
conditions.
The engine should start cleanly and the ECT value
will risequite quickly with smooth progression. If
the ECT signal appears unstable or erratic, the
ECT sensor, electrical connector and wiring
harness to the PCM need to be visually inspected
for damage, chafing or water ingress.
The temperature should rise to approximately 90°C
for a thermostat that has an 88OC value. The signal
value will then fall as cooler coolant enters the
engine.
If the ECT value fails to maintain a constant value
and falls back to lower figures, typically between
60°C (140°F) and 70°C (150°F), the thermostat
cardiagn.com
and its sealing function within the thermostat
housing must be checked.
5. INSTALL a new thermostat.
REFER to: Thermostat - 1.3L Duratec-8V
(Rocam) (303-03 Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L Duratec-I 6V
(Sigma)ll.4L Duratec-I 6V (Sigma)ll .6L
Duratec-16V (Sigma), Removal and
Installation)
IThermostat - 1.25L Duratec-I6V (Sigma)ll.4L
Duratec-16V (Sigma)ll .6L Duratec-16V
(Sigma) (303-03 Engine Cooling - 1.3L
Duratec-8V (Rocam)ll.25L Duratec-I 6V
(Sigma)/l.4L Duratec-16V (Sigma)ll .6L
Duratec-16V (Sigma), Removal and
Installation).
6. Carry out another road test from step 1 using
the same criteria to confirm that the concern
has been rectified.
7. Using the WDS, clear the PCM keep alive
memory (KAM) or electrically erasable
programmable read only memory (EEPROM)
so that new drive values can be learnt.
I
I
G I46258en
 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)llI4L
303-03A-19 Duratec-16V (Sigma)lll6L Duratec-I 6V (Sigma) 303-03A-19
GENERAL PROCEDURES

Cooling System Draining, Filling and Bleeding - 1.3L Duratec-8V

I
(Rocam)/l.25L Duratec-16V (Sigma)/l.4L Duratec-16V
(Sigma)/l.6L Duratec-16V (Sigma)(24 122 0)
Draining 5. Install the radiator drain plug.

laA W A R N I N G : ~ ~ ~ ~ 6. Lower the vehicle.

releasing the cooling
system pressure, cover the coolant
expansion tank cap with a thick cloth to Filling and Bleeding
prevent the possibility of scalding. Failure 1. Removethe radiator bleed plug (if equipped).
to follow this instruction may result in
personal injury.
Release the cooling system pressure by
slowly turning the coolant expansion tank

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cap a quarter of a turn.

2. Fill the coolant expansion tank until coolant

is expelled from the radiator bleed point or
stabilizes at the MAX mark (whichever occurs
first).
3. Install the radiator bleed plug (if equipped).
2. Remove the coolant expansion tank cap.
4. Fill the coolant expansion tank to the MAX
3. Raise and support the vehicle. mark (if necessary).
For additional information, refer to: Lifting
(100-02 Jacking and Lifting, Description
and Operation).
4. Drain the cooling system.
Allow the coolant to drain into a suitable
container.

5. Start and run the engine at 3000 revolutions

per minute (RPM) for two minutes.
6. Fill the coolant expansion tank completely.
7. Install the coolant expansion tank cap.
8. Start and run the engine at 3000 RPM for
another two minutes.

2006.0 Fiesta 1212006 G146259en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll125LDuratec-I 6V (Sigma)ll14L
Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma)
GENERAL PROCEDURES
9. Switch the engine off.

cardiagn.com

2006.0 Fiesta iz1~006 GI 46259en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
303-03A-21 Duratec-16V (Sigma)/l .6L Duratec-16V (Sigma) 303-03A-21
REMOVAL AND INSTALLATION

Water Pump - 1.25L Duratec-16V (Sigma)/l.4L Duratec-16V

(Sigma)/l .6L Duratec-16V (Sigma)(24 404 0)
Removal Loosen the water pump pulley retaining
bolts.
Vehicles built up to 0412005
1. Disconnect the battery ground cable.
For additional information, refer to: Battery
Disconnect (414-01 Battery, Mounting and
Cables, General Procedures).
2. Remove the air cleaner.
For additional information, refer to: Air
-
Cleaner 1.25L Duratec-16V (Sigma)ll.4L

cardiagn.com
Duratec-16V (Sigma)ll .6L Duratec-16V
(Sigma) (303-12 Intake Air Distribution and
Filtering, Removal and Installation).
3. Drain the cooling system.
6. Lower the vehicle.
For additional information, refer to: Cooling
-
System Draining, Filling and Bleeding 1 . 3 ~ 7. Disconnect the degas hose from the coolant
expansion tank.
Duratec-8V (Rocam)ll.25L Duratec-16V
(Sigma)ll.4L Duratec-16V (Sigma)ll .6L
Duratec-16V (Sigma) (303-03 Engine
-
Cooling 1.3L DuratecdV (Rocam)ll.25L
Duratec-16V (Sigma)ll.4L Duratec-16V
(Sigma)ll .6L Duratec-16V (Sigma), General
Procedures).
4. Remove the crankshaft pulley splash shield.

8. Detach the coolant expansion tank and

secure it to one side.

5m AWARNING:D~
not remove the water pump
pulley retaining bolts at this stage as the
pulley is under tension from the accessory
drive belt. Failure to follow this instruction
may result in personal injury.

2006.0 Fiesta 1212006 G I 89080en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)llI4L
303-03A-22 Duratec-16V (Sigma)lIl6L Duratec-16V (Sigma) 303-03A-22
REMOVAL AND INSTALLATION
9. Remove the generator. Discard the gasket.
For additional information, refer to:
-
Generator 1.25L Duratec-16V (Sigma)/l.4L
Duratec-I 6V (Sigma)/l .6L Duratec-I 6V
(Sigma) (414-02 Generator and Regulator,
Removal and Installation).
10. Remove the water pump pulley.

Vehicles built 0412005 onwards

13. Remove the timing belt.

11. Remove the timing belt cover (cover shown
removed for clarity).
cardiagn.com
For additional information, refer to: Timing
-
Belt (303-01 Engine 1.25L Duratec-16V
(Sigma)ll.4L Duratec-16V (Sigma)ll .6L
Duratec-16V (Sigma), ln-vehicle Repair).
14. Drain the cooling system,
For additional information, refer to: Cooling
System Draining, Filling and Bleeding -
1.3L Duratec-8V (Rocam)ll.25L
Duratec-16V (Sigma)ll.4L Duratec-16V (,
(Sigma)ll .6L Duratec-16V (Sigma) (303-03
-
Engine Cooling 1.3L Duratec-8V
(Rocam)ll.25L Duratec-I 6V (Sigma)/l.4L
Duratec-16V (Sigma)ll .6L Duratec-16V
(Sigma), General Procedures).
15. Remove the water pump and the timing belt
tensioner.
Discard the gasket.

12' & A U T I O N : P ~ ~ ~the

~~timing
~ belt and
lower cover from contamination by the
coolant.
Remove the water pump.

2006.0 Fiesta 1212006 GI 89080en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
303-03A-23 Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma) 303-0349-23
REMOVAL AND INSTALLATION
16. Remove the timing belt tensioner from the
water pump.

Installation

cardiagn.com
1. N0TE:lnstall a new water pump gasket.
To install, reverse the removal procedure.

2006.0 Fiesta 1212006 GI 89080en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
303-03A-24 Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma) 303-O3A-24
REMOVAL AND INSTALLATION

Thermostat - 1.25L Duratec-16V (Sigma)/l.4L Duratec-16V

(Sigma)/l .6L Duratec-16V (Sigma)(24 454 0)
Special Tool(s) 4. Disconnect the heater hose from the
I Removerllnstaller, Cooling I thermostat housing.
Hose Clamp
303-397 (24-003)

Removal

cardiagn.com
1. Drain the cooling system.
For additional information, refer to Cooling
System Draining, Filling and Bleeding in
this section. 5. Remove the thermostat housing.
2. Remove the generator. For additional
information, refer to Section 414-02
[Generator and Regulator].
3. Using the special tool, disconnect the
radiator lower hose from the thermostat
housing.

6. N0TE:The thermostat is installed with the

jiggle pin at the top.
Remove the thermostat.

I
,I '

Installation
I.
To install, reverse the removal procedure.

2006.0 Fiesta 1212006 G210040en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)Il.GL Duratec-16V (Sigma)
-- --

REMOVAL AND INSTALLATION

Make sure the rubber seal is located
correctly.
II

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2006.0 Fiesta 1212006 G210040en

 Engine Cooling - 1.3L Duratec-8V
(Rocam)llI25L Duratec-16V (Sigma)llI4L
3-03A-26 Duratec-I6V (Sigma)llm6L
Duratec-16V (Sigma) 303-03A-26
REMOVAL AND INSTALLATION

Radiator(24 254 0) /
'

Special Tool@) 2. Push the cooling fan motor and shroud (.

upwards and then downwards to remove.
I I Remover/lnstaller,
Hose Clamp
Cooling I
303-397 (24-003)

24003

Removal
1. Disconnect the battery ground cable. For
additional information, refer to

cardiagn.com
Section 414-01 [Battery, Mounting and
Cables]. 5. Using the special tool, disconnect the
2. Drain the cooling system. radiator upper hose.
For additional information, refer to Cooling
System Draining, Filling and Bleeding in
this section.
3. Disconnect the cooling fan motor and
cooling fan resistor electrical connectors.

6. Using the special tool, disconnect the

radiator lower hose.

4. Remove the cooling fan motor and shroud.

I.Release the cooling fan motor and shroud
from the retaining brackets.

7. Remove the radiator retainers.

1. Remove the radiator retainer locking screws.

2006.0 Fiesta 1212006 ~ 2 1 0 0 4en

1
 -
Engine Cooling 1.3L Duratec-8V
(Rocam)ll.25L Duratec-16V (Sigma)ll.4L
Duratec-16V (Sigma)/l.6L Duratec-16V (Sigma)
REMOVAL AND INSTALLATION
2. Remove the radiator retainers and grommets.

8. Detach the radiator and the air conditioning

(NC) condenser from the support panel.

cardiagn.com
9m& A U T I O N : S U ~ ~ O the
~ ~ condenser by
positioning it on the support panel.
Slide the N C condenser to detach it from the
radiator

130. Remove the radiator.

Installation
1. To install, reverse the removal procedure.

2006.0 Fiesta 1212006 ~ 2 1 0 0 4 en

1
cardiagn.com