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Discussion Starter · #1 ·
This is reguarding this vehicled I previously listed in the classifieds.

There was no interest so I parked it and now that I have another car lined up to be my daily driver. I borrowed a friends car in the interim but I'm buying a Civic in May from a different friend who just bought a Tacoma for his new daily. Anyway, without all the pressure I was able to come back to this situation with a much clearer head and less emotional investment.

I have been idling the car in the driveway every few days trying to burn up the last of the gas in the tank so it doesn't rot and cause problems later, and I noticed two things.

First is the issue with the temperature sensor reading dropping seems to only happen when the engine is revved and it started happening right after the thermostat was replaced (as well as the air intake gasket due to the first overheating event.) Some searching here turned up the information that the sensor for the temperature gauge runs from somewhere near the thermostat to the ground terminal of the battery so possibly there is an intermittent connection there that I need to check? Anyone else had the temperature guage that seems to be displaying a value correctly suddenly drop (displaying an impossibly low value) as the engine revs? Another thing that started right after the thermostat was replaced is that instead of the guage pointing to the bottom hatch mark before the car is started and starts to warm up it starts about 4mm to the left/under the bottom hatch mark of the temperature guage.

Second, last night I also noticed that the engine fan seems to work...intermittently/strangely? It only turns on when the engine is hot AND the A/C button is active (reguardless of which setting the slider that selects Max A/C, Front Vents, Front/Floor, Floor, Defrost, is on). In addition the cabin fan seems to also need to be on at least the first setting for the engine fan to come on. I do remember the guy that sold it to me told me that "these old Escorts don't run the engine fan unless the A/C button is on". I had at first believed him, but when I found this forum and couldn't find anyone here talking about that I kind of decided he didn't know what he was talking about. The first overheating event happened on the first cold night of winter '22 and I had driven across town with the heat on but not the A/C button on. The overheating happened as I had the car idling in the driveway at my destination, perhaps because the engine fan wasn't running? Has anyone here ever heard of the engine fan not working without the A/C button and the cabin fan turned on? Maybe the guy I brought it from did some sort of aftermarket wiring and didn't want to explicitly state that since I hadn't made an offer or paid for the car it at that point in the conversation.

There is a third thing that might be part of the problem although it's a longer shot. Right after I bought the car late in '22 I had to replace my plugs, wires, fuel pump, fuel filter, and a few injectors when I got the car because it developed a misfire code and had a long crank issue that didn't turn up in my test drive. I wonder if maybe the catalytic converted might be clogged or something causing backpressure in the exhaust...like I said it's a long shot possibility but I was having emissions (o2 sensor) codes and replaced both of those but there's still a rattle sound when the engine is under load and the smell of exhaust in the cabin that also started right after the overheating incident. The exhaust coming out of the tailpipe still feels like it's coming out with strong pressure so that might be a completely different issue.

I still need to have another mechanic take a look at the engine and give me a second opinion on that because I don't actually have any verification that there is coolant leaking and none has leaked during this testing so I am starting to doubt the mechanic that told me he thought the engine is warped or cracked, so I am considering these other possibilities before I take the car to a junkyard. It might not be reliable enough in this condition to be a daily driver but I wouldn't mind having it just for a fun weekend ride.
 

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Discussion Starter · #3 ·
cooling fan will only come on around 230* under normal operating conditions. a/c request bypasses this setting.
Is there a scenario where the cooling fan doesn't come on at 230* as it should but the a/c request still works? I'm assuming here but I would guess that the ECM is getting temperature data from a sensor, but maybe not the same sensor connected to the dash guage? So either the sensor input to the ECM is bad or the signal from the ECM to the fan is bad? Or, the third option, the engine isn't actually reaching 230* when I'm just idling it in the driveway...
 

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pcm reads temp data from the temp sensor that comes off of the thermostat housing, leading into the heater hose that has 2 wires. the single wire sensor is for gauge function only and is not meant to be a scientific measurement. you would need a scan tool to read live data to see wht the pcm is seeing. if the a/c function operates and the engine side isnt, it indicates the fan relay circuits are more or less functioning but could be missing the pcm input. again, need a scan tool to read data.

here is a video I made many years ago. one of my first on the channel so its not the best. but explains how the system operates

 

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Yours being a 96, you can get a ford escort/tracer service manual from ebay failrly cheaply, but a more valuable manual is the Electrical and Vacuum Troubleshooting Manual, (EVTM) which has all of the wiring diagrams in it, and pictorials showing the location of components. While the service manuals pretty much cover all years of the 2nd gen escorts, the EVTMs do change each year, so get the one for a 96.

The way the fans work is a little confusing sometimes, and being as old as your car is, may be no long be working as it originally should. We live in deep south TX and visit relatives in north MX fairly often. I have wired around the OEM fan relays with a wire to the positive battery terminal - so the cooling fan runs constantly, while waiting for an hour or two in the creeping lines coming back into the USA. While my cooling fans will run when the engine gets hot enough, I prefer to avoid those temperature excursions, by just running the fan continuously. I disconnect the wire once we are across the puente internacional and driving at normal speeds.
 

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What Denisond3 said about getting the EVTM is good as gold advice. It kind of sounds like the issue we had last summer where the contacts in the High Speed Fan Relay burned out. This relay feeds power to the Low Speed Fan Relay which feeds power to the low speed windings on the fan motor until a certain temperature is reached (I'll guess 235 because right now I'm feeling too tired to look it up) then it switches the Low Speed Fan Relay OFF and sends power directly over to the high speed windings on the fan. You can guess what happened, just when the fan was needed to turn fast the High Speed Fan Relay shut it off! With our first Escort it was the Fan Power Relay in the fuse box that failed and I made a jumper to bypass it until it was replaced. Our son did me one better and ran the jumper into the cabin and put a switch in it so he could the fan on/off without having to get out of the car. While your waiting for the EVTM to arrive hit up all the salvage yards you can to get in a supply of relays, all of them! '95's and '96s have the same fan relays, '94s have one that is different, but is wired and works the same. Don't know about other Escorts. I used a multimeter and a simple DC toy train transformer to test the relays. You can use a candy thermometer available from bigger supermarkets to check your actual coolant temp.
 

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That's sound advise too. I guess I just belong to a junkyard culture. I've got 1 relay, out of dozens, that didn't work. All of the Escorts I've found in the salvage yards in the last 3 years had waaaay less than half the miles of ours so I figure I'll get at least 100,000 miles out of their relays.
 
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