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Engine Runs Hot and/or Engine Oil Mixed with Engine Coolant in Engine Coolant Recovery Reservoir (Replace Cylinder Head Assembly) This bulletin is revised to provide updated claim information as well as parts information about the release of a remanufactured cylinder head. This bulletin supercedes bulletin 96-T-65A, which should be discarded. MODELS AFFECTED: 1991-1997 Saturn vehicles equipped with SOHC (LK0-1991-1994, L24-1995-1997) engines. CONDITION: Engine may run hot and/or have engine oil mixed with engine coolant. This condition may be noticeable when checking coolant recovery reservoir level. CAUSE: Some 1991-1997 SOHC engines may develop a crack on or near the camshaft journals and surrounding casting areas allowing engine oil to mix with engine coolant. CORRECTION: Refer to the following procedure to locate the area where the engine oil is leaking into engine coolant passages. PROCEDURE: IMPORTANT: When required, refer to the appropriate year service manuals when performing the following procedures. 1. Remove camshaft from cylinder head. 2. Pressure test cooling system.

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6.0L DIESEL FUEL IN ENGINE COOLANT DIAGNOSTICS FORD: 2003-2005 Excursion 2003-2007 F-Super Duty 2004-2008 E-Series ISSUE Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.OL engine may exhibit fuel in the engine coolant, due to leaks in the cylinder head fuel injector area. Symptoms may include fuel in engine coolant and coolant expulsion from the degas bottle. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Inspect the degas bottle for evidence of fuel in engine coolant. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics. NOTE IT IS VERY IMPORTANT TO ENSURE A COMPLETE FLUSHING OF THE ENGINE COOLING SYSTEM IS PERFORMED TO REMOVE ALL CONTAMINANTS FOLLOWING REPAIR. 1. Drain coolant from cooling system. 2. Remove all injectors from both cylinder heads. Refer to Workshop Manual (WSM), Section 313-04C. 3. Wipe injector bore clean of oil and fuel then apply a thin layer of bubbly type liquid hand soap, dish soap or laundry soap inside each injector bore. Ensure injector sleeve lip and cylinder head casting are coated with a soap layer. (Adding a small amount of water to the soap aids in creating bubbles) 4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant) 5. Apply 5-10 psi (34-69 kPa) of air pressure to sealed cooling system. It is suggested to use a hand operated pressure tester or regulated shop air with tee in degas hose to degas bottle. NOTE MORE THAN 10 PSI (69 kPa) AIR PRESSURE CAN PUSH THE SOAP FROM THE LEAK POINT AND NO BUBBLES WILL BE PRESENT OR CREATED, MAKING DIAGNOSIS DIFFICULT. 6. Inspect each injector bore for bubbles. (A light and mirror or bore-scope may aid in pinpointing a leak location.) If bubbles are observed, determine if bubbles originate from the injector sleeve lip (Figure 1) or cylinder head casting. (Figure 2) Refer to cutaway view of the cylinder head. (Figure 3) a. Replace the injector sleeve if found to be leaking at sleeve lip, refer to WSM 303-04C. b. Replace cylinder head if leaking through casting, refer to WSM 303-01C. c. Flush cooling system, refer to another applicable Technical Service Bulletin (TSB) for proper cooling system flush procedures.

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Models: 2004-2006 Buick Rainier 2001-2006 Cadillac Escalade Models 2001-2006 Chevrolet Avalanche, Blazer, Silverado, Suburban, Tahoe, TrailBlazer Models 2001-2006 GMC Envoy, Jimmy, Sierra, Yukon Models 2001-2004 Oldsmobile Bravada 2005-2006 Saab 9-7X Some vehicles may experience a gradual coolant loss over time. A very low percentage of cylinder head(s) manufactured with an embossed Castech logo may develop a porosity crack in a very specific area. Inspect the cylinder head assembly to determine if the casting was manufactured by Castech. This can be accomplished by inspecting for their casting logo located on top of the intake port, under the rocker arm support rail and in the spring deck cavity portion of the cylinder head. Important: If the cylinder head(s) are Not a Castech casting, follow normal diagnostic procedures in SI to determine the cause of the coolant loss. Refer to the following illustrations on how to identify Castech casting and/or the very specific areas of the cylinder head(s) for a coolant leak from porosity.

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SUBJECT: Engine Coolant Temperature Sensor Related Diagnostic Trouble Code(s) and/or the Following Conditions: Hard Start, Erratic Idle, Rough Running. Engine Overheating, Low and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated. (Replace Engine Coolant Temperature Sensor with New Design Sensor- P/N 21025106) MODELS AFFECTED: 1991-2001 Saturn S-Series vehicles CONDITION: Customers may comment about various driveability and/or engine operating concerns including: hard start, erratic idle, rough running, engine overheating, low and/or leaking coolant, and/or Service Engine Soon lamp illuminated. CAUSE: This condition may be caused by a cracked engine coolant temperature sensor. CORRECTION: Replace engine coolant temperature sensor, inspect and if necessary replace sensor harness connector. Refer to procedure in this bulletin to replace engine coolant temperature sensor and Parts Requirements for specific parts information. PROCEDURE 1. Disconnect engine coolant temperature sensor electrical connector and inspect sensor and connector terminals for corrosion and/or evidence of engine coolant. ^ If terminals are corroded or if there is evidence of engine coolant proceed to step 4. ^ If terminals are not corroded and there is no evidence of engine coolant, reconnect the electrical connector and continue to next step.

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CATEGORY TYPE: Engine-03 CATEGORY: Emission Controls CORPORATION NO.: 01-06-04-005 SUBJECT: Engine Coolant Temperature Sensor Related Diagnostic Trouble Code(s) and/or the Following Conditions: Hard Start, Erratic Idle, Rough Running. Engine Overheating, Low and/or Leaking Coolant, and/or Service Engine Soon Lamp Illuminated. (Replace Engine Coolant Temperature Sensor with New Design Sensor- P/N 21025106) MODELS AFFECTED: 1991-2001 Saturn S-Series vehicles CONDITION: Customers may comment about various driveability and/or engine operating concerns including: hard start, erratic idle, rough running, engine overheating, low and/or leaking coolant, and/or Service Engine Soon lamp illuminated. CAUSE: This condition may be caused by a cracked engine coolant temperature sensor. CORRECTION: Replace engine coolant temperature sensor, inspect and if necessary replace sensor harness connector. Refer to procedure in this bulletin to replace engine coolant temperature sensor and Parts Requirements for specific parts information. PROCEDURE