Duratec- D20:
My cooling fans never came on. The engine heats up, but my guess (without a coolant temp gauge) is that it hovers around 180. This is an all aluminum engine, but it has the same radiator as the mixed Zetec. Ford did the same thing in the Aerostars- the 2.3 and 3.0 had the same radiator as the 4.0. Our motors are overcooled. My Focus would heat up quickly, but soon after the cold weather hit here- I noticed a sudden drop in my fuel econmy. Now the cold weather here came and went, and I was still on the same tank of fuel so it WAS NOT ethanol that caused me to go from 32ish to 26ish. These are guesses going by my usual usage at certain FE on my fuel gauge- not super accurate. I had a similar experience in my old Aero*, so I tried the same fix I used before. I blocked off part of the radiator with cardboard. The temps then stayed around 60F for more than a month. I never had a hint of overheating, and the fans STILL did not come on. The only time the fans did come on was while I was trying to figure out a problem with a friend's battery and charged it for 30 mins with mine idling.
Now the temps are dipping down into the 30's at night and the 40's during the day, and I've not noticed a difference in the fuel economy from when the temps were in the 60's. If you pull the plastic latch cover off that sits over the top of the grille back to the radiator (pull up slightly and slide towards engine after removing plastic screw & pin anchors), you will see that there are two spaces on either side of the latch support that are 8.5" x 17.5". I filled both these spots with cardboard, and folded the bottom of the cardboard to fit inside the splashguard at the bottom. After the testing period, I duct taped the cardboard and re-installed to protect the cardboard from rain. The car seems to run much better in the cold ambient temps, and the fans still do not come on. I think it would take 15 mins of idling to get the primary fan to turn on, and, from my charging experience at 60F, it goes off after about 5 mins.
Beware Zetec owners, this was done on an 05 Duratec, later D20's and D23 owners, try cautiously. I have not done any data logging with my XCal2. I am also running the stock program at the moment. XCal2 programs generally advance spark, so you might want to retard spark in the program instead to be completely safe and to avoid Ford's -10 knock sensor setting. D20 owners, this seems to be helping avoid cold ambient temp FE losses, however where I live there is not blended fuel because our temps barely go below 30 for 2 weeks. Your FE experience will be different, but my guess is that it will help some. IF anyone want's to do datalogging on an XCal with a D20 PLEASE post in my fuel economy thread. I'm too freaking busy at the moment. OH yeah.. instant heater too. [

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