Supercharger Cooling

Special Tool(s)

	3-Way HD Antifreeze Coolant Test Kit 328-2050-62291 or equivalent
	Coolant/Battery Refractometer 300-ROB75240 or equivalent
	D-Gas Adapter 300-OTC014-R1068 or equivalent
	Radiator Tester STN12270 or equivalent

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: Check the coolant and engine oil levels. Top off the coolant level if needed. If there is engine coolant in the engine oil, the cause must be corrected and the oil changed or major component damage can occur.

NOTICE: 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 Supercharger Cooling System Flushing . Failure to follow these instructions may damage the SC cooling system.

NOTICE: The SC cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft® Orange Antifreeze/Coolant.

NOTE: During normal vehicle operation, Motorcraft Orange Antifreeze/Coolant may change color from orange to pink or light red. As long as the coolant is clear and uncontaminated, this color change does not indicate the coolant has degraded nor does it require the coolant to be drained, the system to be flushed, or the coolant to be replaced.

1. Verify the customer's concern by operating the engine to duplicate the condition.

2. Inspect to determine if any of the following mechanical or electrical concerns apply.

  Visual Inspection Chart

3. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary.

4. Inspect the coolant condition in the following sequence:

   1.  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.

      Allow the engine to cool. Once pressure is released, remove the pressure relief cap.

   2. NOTICE: The Supercharger (SC) cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft® Orange Antifreeze/Coolant.

      Inspect the coolant appearance:
      • Discoloration may indicate that incorrect coolant may have been added to the system. Use of incorrect (green or yellow in color) coolant degrades the corrosion protection of Motorcraft® Orange Antifreeze/Coolant. Addition of Motorcraft® Specialty Green Engine Coolant may cause the color to appear to be a murky green-brown color. The addition of Motorcraft® Premium Gold Coolant, however, may not change the color or appearance of the orange colored coolant. Detection of contamination with Premium Gold Engine Coolant is determined by the presence of nitrite. If contamination with Motorcraft® Premium Gold Engine Coolant is suspected, test the coolant with the 3-Way HD Antifreeze Coolant Test Kit. Follow the nitrite testing directions in the kit to determine if nitrite is present in the system. If nitrite is present, flush the system and refill with the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. Refer to Supercharger Cooling System Flushing .
      • A darker orange 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 Motorcraft® Orange Antifreeze/Coolant. Refer to Supercharger Cooling System Flushing .
      • A light or 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 Motorcraft® Orange Antifreeze/Coolant. Refer to Supercharger Cooling System Flushing .
   3. If the coolant appearance is acceptable, test the coolant freezing point range with the Coolant/Battery Refractometer. The coolant concentration should be maintained within 48% to 50%, which equates to a freeze point between -34°C (-30°F) and -37°C (-34°F). If the vehicle is driven in cold climates less than -37°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 48/52 to 50/50 (freeze protection -34°C (-30°F) and -37°C (-34°F)) 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.
   4. Check the coolant system conditions:
      • If the coolant level is low, add Motorcraft® Orange Antifreeze/Coolant Prediluted.
      • If the coolant tests weak, remove some of the coolant and add Motorcraft® Orange Antifreeze/Coolant Concentrated until the readings are within acceptable levels.
      • If the coolant tests strong, remove some of the coolant and add distilled water until readings are within acceptable levels.

5. If the concern remains after the inspection, determine the symptom(s). GO to Symptom Chart .

6. Verify the cooling system is correctly filled and bled. Refer to Supercharger Cooling System Draining, Filling and Bleeding .

Symptom Chart

Component Tests

Pressure Test

1. Turn the engine OFF.

2.  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.

   Check the coolant level. Refer to Supercharger Cooling System Draining, Filling and Bleeding .

3. Connect the D-Gas Adapter to the degas bottle nipple. Install the Radiator Tester to the quick connect fitting of the D-Gas Adapter.

4. NOTE: If the plunger of the pump is pressed too fast, an erroneous pressure reading will result.

   Slowly press the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained.

5. If the pressure relief cap does not hold pressure, remove and wash the pressure relief cap in clean water to dislodge all foreign particles from the gaskets. Check the sealing surface in the filler neck.

6. If 110 kPa (16 psi) cannot be reached, install a new pressure relief cap. If more than 165 kPa (24 psi) shows on the gauge, install a new pressure relief cap.

7. NOTE: If the pressure drops, check for leaks at the CAC hoses or other system components and connections. Any leaks which are found must be corrected and the system rechecked.

   NOTE: The SC system is not connected to the main engine cooling system.

   Pressurize the SC cooling system as described in Step 4 (using a pressure relief cap that operates within the specified upper and lower pressure limits). Observe the gauge reading for approximately 2 minutes; refer to General Specifications. Pressure should not drop during this time.
   • If the pressure drops and no external leak is found, the CAC may be the cause. Remove and inspect the CAC . Install a new CAC if necessary.

8. Release the system pressure by loosening the pressure relief cap. Check the coolant level and replenish, if necessary, with the correct coolant mixture. Refer to Supercharger Cooling System Draining, Filling and Bleeding .

Radiator Leak Test, Removed From the Vehicle

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

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

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