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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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Draining 1. Bring the engine to normal operating temperature and turn the engine off. With the cooling system under pressure, inspect cooling system hoses and clamped hose connections for leaks, excessive deterioration or contact wear. Inspect radiator installation retention. Note any discrepancies and proceed. 2. WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and replaced. CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant VC-7-A meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types. NOTE: Less than 80 percent of coolant capacity can be removed from the engine. Dirty, rusty or contaminated coolant requires replacement. Drain engine coolant as follows: Open radiator draincock to drain the coolant system. Disconnect radiator overflow hose from radiator filler neck connection. Remove radiator coolant recovery reservoir and empty the fluid. Flush radiator coolant recovery reservoir with clean water. Drain and reinstall radiator coolant recovery reservoir and radiator overflow hose and clamp to radiator filler neck. Correct, repair or install new components found to be inoperative in Step 1. Filling and Bleeding with RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling and Bleeding without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system:

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CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be recycled or disposed of correctly. CAUTION: All vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant VC-7-A or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same type of coolant that is present in the system. Do not mix coolant types. NOTE: The addition of Cooling System Stop Leak Pellets, VC-6, darkens Motorcraft Premium Gold Engine Coolant from yellow to golden tan. NOTE: Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.

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Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.0L engine may experience engine oil, transmission fluid or diesel fuel contaminating the cooling system. This flushing procedure is to be performed after the source of the cooling system contamination has been identified and repaired. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Follow the steps in sequence to effectively repair the vehicle: • Drain cooling system contaminates. • Clean cooling system with Simple Green® Heavy Duty Cleaner and Degreaser. • Clean cooling system with Motorcraft® Engine Cooling System Iron Cleaner. NOTE ALL STEPS MUST BE COMPLETED IN ORDER TO PROPERLY CLEAN THE COOLING SYSTEM. ANY DEVIATION FROM THE SERVICE PROCEDURE WILL RESULT IN SHORTENED COOLANT PROTECTION AGAINST CORROSION IN THE COOLING SYSTEM. 1. Determine cooling system condition. Is the contaminated coolant in a flowable, liquid or milky state? a. No – Do not proceed as this procedure does not apply. (Non-Flushable Examples Figures 1-3)

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Draining WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be recycled or disposed of correctly. CAUTION: Care must be taken to ensure the accessory drive belt does not become contaminated with engine coolant. CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specifications ESE-M97B44-A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant VC-7-A or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always refill the cooling system with the same coolant that was drained from the system. Do not mix coolant types. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise. When the pressure is released, remove the pressure relief cap. 2. NOTE: Less than 80% of coolant can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the oil cooler. Close the radiator draincock when finished. Filling and Bleeding With RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling and Bleeding Without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system: