303-03A+Engine+Cooling

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Engine Cooling - 1.0L EcoBoost

(74kW/100PS)/1.0L EcoBoost
(103kW/140PS) (YY) - Specifications
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LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES
SPECIFICATIONS
Material: WSS-M97B44-D (Antifreeze)
CAPACITIES
INITIAL FILL VOLUME
1.1L Duratec 5.1 L
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1.0L EcoBoost (Manual Transmission) 5.6 L
1.0L EcoBoost (Automatic Transmission) 7.2 L
ANTIFREEZE
PERCENT ANTIFREEZE/COOLANT TO DISTILLED WATER FREEZE PROTECTION
42/58 -26°C
58/42 (Extreme Cold Climates) -50°C
THERMOSTAT
Thermostat (starts to open) 92 ± 2°C
Thermostat (fully open) 106°C
Cylinder Block Thermostat (starts to open) 50 ± 2°C
Cylinder Block Thermostat (fully open) 65°C
COOLING SYSTEM PRESSURE
DESCRIPTION PRESSURE
Coolant expansion tank cap release pressure 1.4 bar
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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine Cooling -
Component Location
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Description and Operation
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Item Description
1 Coolant expansion tank
2 Coolant pump
3 Electric coolant pump
4 Radiator
5 Thermostat
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Item Description
1 Cooling fan
2 Oil Cooler
3 Thermostat housing with thermostat
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(103kW/140PS) (YY) - Engine Cooling -
Overview
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Special features
A three circuit cooling system is used on this engine. In addition to the conventional
thermostat for the small and large coolant circuit, a further thermostat for controlling a
mini coolant circuit is used.
The mini coolant circuit means that the coolant only flows through the exhaust side of the
cylinder head during the first stage of the warm-up phase. From here the coolant
arrives at the oil cooler via the heat exchanger and from there it is passed to the coolant
pump. In this phase there is no coolant flow in the cylinder block nor on the intake side of
the cylinder head.
This leads to rapid warm-up of the engine and the engine oil, through which the friction at
the lubrication points is reduced at an early stage.
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Furthermore, in addition to the usual mechanical coolant pump, an electric coolant pump
is installed in the coolant circuit.
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Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

EcoBoost (103kW/140PS) (YY) - Engine Cooling - System Operation and Component
Description
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System Diagram
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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Thermostat housing – small/large coolant circuit and bypass valve
5 Cylinder head – exhaust side
6 Short block thermostat
7 Cylinder block and cylinder head – intake side
8 Mechanical coolant pump
10 Turbocharger
11 Radiator
System Operation
Cooling system function
The cooling system is controlled in 3 phases.
Phase 1
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When the engine is cold, the small/large coolant circuit thermostat and the short block
thermostat are closed.
The mechanical coolant pump delivers the coolant only to the exhaust-side part of the
cylinder head. In this phase, the coolant in the coolant jacket around the cylinder and in the
intake-side part of the cylinder head remains motionless.
Below a coolant temperature of approximately 50°C and below an engine speed of
approximately 3000 rpm, only the exhaust-side part of the cylinder head is cooled.
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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Casing – Thermostat – Small/large coolant circuit and bypass valve
10 Turbocharger
11 Radiator
The coolant flows from the part of the cylinder head on the exhaust side into the thermostat
housing in the small/large coolant circuit and bypass valve and, from there, via the heater
core to the oil cooler and then back to the coolant pump.
In addition, part of the coolant flows from the short block through the electrical coolant
pump and, from there, on past the exhaust gas turbocharger to the coolant expansion tank
and then back to the coolant pump.
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Item Description
1 Coolant flow from oil cooler
2 Coolant flow to heat exchanger
3 Small/large coolant circuit thermostat
4 Bypass valve
5 Coolant flow to mechanical coolant pump
6 Coolant flow from exhaust-side part of the cylinder head
Below a coolant temperature of approximately 50°C and below an engine speed of
approximately 3000 rpm, the small/large coolant circuit thermostat and the bypass valve are
closed.
Item Description
1 Coolant flow from oil cooler
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2 Coolant flow to heat exchanger

4 Bypass valve
5 Coolant flow to mechanical coolant pump
6 Excessive coolant flow from exhaust-side part of the cylinder head
If the engine speed exceeds approximately 3000 rpm, the bypass valve opens. The now
increased coolant pressure from the engine opens the bypass valve so that the increase
pressure can escape directly to the intake side of the coolant pump.
Phase 2
The short block thermostat opens at a coolant temperature of 50 °C and is completely open
at 85 °C.
As with a conventional system, this opens the small coolant circuit.
The coolant pump now also delivers the coolant to the cooling jacket around the cylinder,
washes around it and enters the entire cylinder head via the bore holes.
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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
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10 Turbocharger
11 Radiator
Phase 3
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Item Description
4 Bypass valve
7 Coolant flow to the radiator
The small/large coolant circuit thermostat opens at a coolant temperature of 92 °C and is
completely open at 106 °C. At the same time, the bypass valve thermostat closes. This
ensures that the entire coolant flow, regardless of the coolant pressure, is always routed via
the radiator.
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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
4 Casing – Thermostat – Small/large coolant circuit and bypass valve
10 Turbocharger
11 Radiator
Component Description
Electric coolant pump
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With this engine, in addition to the usual mechanical coolant pump, an electric coolant pump
is installed in the coolant circuit.
The pump is secured onto the cooling fan housing via a retaining device.
The coolant pump is only activated whenever the coolant temperatures exceeds a
critical value. This can occur in particular if the engine has been operated at a high load for
a long time and is then parked immediately afterwards. For example, after a long motorway
journey at high speed, with subsequent parking at a service station. This can lead to an
excessive build-up of heat around the engine after the engine has been switched off.
The PCM (powertrain control module) activates the electric coolant pump to prevent any
damage due to this build-up of heat.
It can therefore be the case that the electrical coolant pump continues to run for a certain
period of time.
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Item Description
1 Reservoir
2 Heat exchanger
3 Oil cooler
10 Turbocharger
11 Radiator
With the electrical coolant pump activated, the coolant flows through the exhaust gas
turbocharger to the coolant expansion tank and from there through the mechanical coolant
pump in the short block to the electrical coolant pump.
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(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Engine Cooling
System Draining, Vacuum Filling and Bleeding
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General Procedures
General Equipment
Cooling System Vacuum Tester and Refiller
Fluid Container
Draining
1. Refer to: Engine Cooling System Health and Safety Precautions (100-00 General
Information, Description and Operation).
2.
WARNING: When releasing the cooling system pressure, cover the coolant
expansion tank cap with a thick cloth to prevent the possibility of scalding. Failure
to follow this instruction may result in personal injury.
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3. Remove the following items:
• Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
4.
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5.
6.
7. NOTE: Be prepared to collect escaping fluid.

Use the General Equipment: Fluid Container
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Loosen: 2 turn(s)
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8. Torque: 2 turn(s)
9. Torque: 10 Nm
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10. Torque: 10 Nm
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11.
12. Install the following items:
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• Refer to: Front Bumper Cover (501-19 Bumpers, Removal and Installation).
Filling
NOTE: Always follow the manufacturer's instructions when handling the equipment.
1. Refer to: Specifications (303-03A Engine Cooling, Specifications).
2. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill
and bleed the system.
Use the General Equipment: Cooling System Vacuum Tester and Refiller
3. Fill the coolant expansion tank to the top of the MAX FILL line.
4. Install the degas bottle coolant expansion tank cap until it contacts the hard stop.
Bleeding
1. Turn the climate control system off.
2. Start the engine and increase the engine speed to 3,500 rpm and hold for 30 seconds.
3. Turn the engine off and wait for 1 minute to purge any large air pockets from the
cooling system.
4. Check the engine coolant level in the coolant expansion tank and, if necessary, fill to the
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top of the MAX FILL line.
5. Start the engine and let it idle until the engine reaches normal operating temperature
and the thermostat is fully open.
6. Increase the engine speed to 3,500 rpm and hold for 30 seconds.
7. Allow the engine to idle for 30 seconds.
8. Turn the engine off for 1 minute.
9. Repeat steps 6 through 8 a total of 10 times to remove any remaining air trapped in the
system.
10. Check the engine coolant level in the coolant expansion tank and, if necessary, fill to the
top of the MAX FILL line.
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(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Coolant Pump
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Removal and Installation
Removal
1. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03A Engine
Cooling, General Procedures).
2. Loosen: 2 turn(s)
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3. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).
4.
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Vehicles without Auto-Start-Stop

5.
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Vehicles with Auto-Start-Stop
6.
Installation
Vehicles with Auto-Start-Stop
1. NOTE: Only tighten the bolts finger tight at this stage.
1. NOTE: Make sure that new components are installed.
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Vehicles without Auto-Start-Stop
1. NOTE: Make sure that new components are installed.
All vehicles
3. Torque:
1-5 10 Nm
6-7
Stage 1:15 Nm
Stage 2:90°
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5. Refer to: Accessory Drive Belt (303-05A Accessory Drive, Removal and Installation).
6. Torque: 25 Nm
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(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cooling Fan Motor
and Shroud—6-Speed Manual Transmission – 6MX65
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Removal
NOTE: Removal steps in this procedure may contain installation details.
1. Refer to: Air Cleaner (303-12A Intake Air Distribution and Filtering, Removal and
Installation).
2.
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3.
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4. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation).
5.
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6.
7.
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Installation
1. To install, reverse the removal procedure.
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(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Cylinder Block
Thermostat
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General Equipment
Hose Clamp Remover/Installer
Removal
2. Refer to: Generator - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

EcoBoost (103kW/140PS) (YY) (414-02 Generator and Regulator, Removal and
Installation).
3. Use the General Equipment: Hose Clamp Remover/Installer
4. NOTE: Make sure that new O-ring seals are installed.

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Torque: 10 Nm
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Installation
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(103kW/140PS) (YY) - Electric Coolant
Pump
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1. Refer to: Charge Air Cooler (CAC) Coolant Pump (303-12A Intake Air Distribution and
Filtering, Removal and Installation).
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(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Radiator—6-Speed
Manual Transmission – 6MX65
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Removal
2. Refer to: Cooling Fan Motor and Shroud - 6-Speed Manual Transmission – 6MX65 (303-
03A Engine Cooling, Removal and Installation).
3.
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4.
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5.
Installation
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(90kW/120PS)/1.0L EcoBoost (103kW/140PS) (YY) - Thermostat
Housing
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General Equipment
Hose Clamp Remover/Installer
Removal
2.
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3.
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Use the General Equipment: Hose Clamp Remover/Installer

Use the General Equipment: Hose Clamp Remover/Installer
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6. Torque: 10 Nm
Installation

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Engine Cooling - 1.0L EcoBoost

LUBRICANTS, FLUIDS, SEALERS AND ADHESIVES

Material: WSS-M97B44-D (Antifreeze)

INITIAL FILL VOLUME

1.1L Duratec 5.1 L

1.0L EcoBoost (Automatic Transmission) 7.2 L

PERCENT ANTIFREEZE/COOLANT TO DISTILLED WATER FREEZE PROTECTION

58/42 (Extreme Cold Climates) -50°C

Thermostat (starts to open) 92 ± 2°C

Thermostat (fully open) 106°C

Cylinder Block Thermostat (starts to open) 50 ± 2°C

Cylinder Block Thermostat (fully open) 65°C

COOLING SYSTEM PRESSURE

Coolant expansion tank cap release pressure 1.4 bar

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

Description and Operation

Engine Cooling - 1.0L EcoBoost

Description and Operation

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

Description and Operation

2 Coolant flow to heat exchanger

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

7. NOTE: Be prepared to collect escaping fluid.

12. Install the following items:

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

Removal and Installation

Vehicles without Auto-Start-Stop

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

Removal and Installation

1. To install, reverse the removal procedure.

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

Removal and Installation

2. Refer to: Generator - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost (90kW/120PS)/1.0L

3. Use the General Equipment: Hose Clamp Remover/Installer

4. NOTE: Make sure that new O-ring seals are installed.

1. To install, reverse the removal procedure.

Engine Cooling - 1.0L EcoBoost

Removal and Installation

Removal and Installation

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

Removal and Installation

1. To install, reverse the removal procedure.

Engine Cooling - 1.0L EcoBoost (74kW/100PS)/1.0L EcoBoost

Removal and Installation

5. NOTE: Be prepared to collect escaping fluid.

1. To install, reverse the removal procedure.

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