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Removal NOTE: Removal of the vertical EGR cooler is not required to service the thermostats. 1. Remove the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section. 2. Remove the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 3. Using a mirror, find the end of the upper radiator hose spring clip. Remove the spring clip, disconnect the upper radiator hose from the thermostat housing and position the upper radiator hose aside. 4. Remove and discard the nut and the vertical EGR cooler lower clamp. 5. Remove the bolt and the vertical EGR cooler lower bracket. 6. NOTE: Vertical EGR cooler removed from art for clarity. Disconnect the wiring from the heater return tube. 7. Remove the 2 bolts and position out the LH heater return tube. • Remove and discard the O-ring seal. 8. NOTE: The 6.4L diesel engine uses 2 thermostats. Remove the 4 bolts, the collar and the thermostat housing. • Lift the bottom of the collar up and rotate toward the engine to remove. 9. NOTICE: If the thermostats are contaminated with engine oil, new thermostats must be installed. Reusing a thermostat that has been exposed to engine oil may result in engine overheating. Remove the thermostats and the gasket from the thermostat housing. • Discard the gasket. Installation 1. Install a new gasket and the thermostats into the thermostat housing. 2. Install the thermostat housing, the collar and the 4 bolts. • Tighten to 13 Nm (115 lb-in). 3. NOTE: Vertical EGR cooler removed from art for clarity. NOTE: Install a new O-ring seal. Install the LH heater return tube and the 2 bolts. • Tighten to 13 Nm (115 lb-in). 4. Connect the wiring to the heater return tube. 5. Position the lower vertical EGR cooler bracket and loosely install the bolt. 6. Install a new vertical EGR cooler lower clamp. Tighten the clamp nut in 3 stages. • Stage 1: Tighten the nut to 10 Nm (89 lb-in). • Stage 2: Loosen the nut 720 degrees (2 complete turns). • Stage 3: Tighten the nut to 8 Nm (71 lb-in). 7. Tighten the lower EGR cooler bracket bolt. • Tighten to 62 Nm (46 lb-ft). 8. Connect the upper radiator hose to the thermostat housing. Install the spring clip. • Verify the spring clip is correctly seated. 9. Install the degas bottle. For additional information, refer to Degas Bottle — 6.4L Diesel in this section. 10. Install the upper cooling fan shroud. For additional information, refer to Cooling Fan Shroud — 6.4L Diesel, Upper in this section.

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On many PSA models fitted with the Hdi (common rail) engine it is necessary to service the particulate filter (FAP) system every 40,000 to 50,000 miles. This will be indicated via the instrument cluster in the form of a ‘Particulate’ system warning. The following components make up the FAP system: Control module (normally located in the cabin) Particulate filter (part of the exhaust system) Fluid reservoir (Integrated in the fuel tank) Pump Injector The FAP system was introduced on PSA vehicles back in the year 2000 when it was developed to reduce diesel particulate levels in engine emissions through filtration. The system operates by burning off particles caught in the filter which make up part of the exhaust system. To enable this ‘burning off’ process the exhaust gas temperature must be raised to approximately 500°C, this is achieved by changing the characteristics of the diesel before combustion by the means of an additive. The additive is held in a separate fuel reservoir (approx 5 litres) which is connected via a pump to an injector fitted into the diesel fuel system (normally in the fuel tank). A proportional amount of additive is injected under the control of the FAP ECU when the diesel tank is filled up, for this to be accurate the system needs to have information from the ‘Fuel level’ sensor to determine what quantity to inject. When the ‘Particulate’ warning lamp is displayed it is essential to diagnose the FAP system first to determine the problem. If the fault describes ‘Fluid level low’ or ‘Filter blocked’ then both areas need to addressed simultaneously as it is normal to find that when the reservoir is empty (approx 5L) then the filter has come to the end of its serviceable life. Please check specific Peugeot / Citroen information for service intervals and capacities,

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Note: There are two different fuel filter systems. In system 1, the fuel filter is located on the engine, under the engine cover. In system 2, the fuel filter is located to the left in the engine compartment, on the strut tower. Special tools, testers and auxiliary items required Suction pump VAS 5226 Remove engine cover Removing: Upper engine cover, removing and installing . Remove plug – arrow – from fuel filter housing water drain connector. Extract diesel fuel via water drain connection located on the side of the fuel filter housing – arrow – using V.A.G 1390 and V.A.G 1390/1 . Seal off oil plug again and tighten to 3 Nm. Remove line connectors for fuel lines Remove screws – arrows – along with connection lines to fuel filter housing Removing fuel filter cover: Remove screws – arrow – for fuel filter housing and remove cover Remove fuel filters – 3 – from cover – 1 – Note: Observe waste disposal regulations! Installing: Install new fuel filters – 3 – and replace seal – 2 – Install fuel filter cover – 1 – . Tighten screws – arrows – for fuel filter cover (8 Nm) Install line connectors for fuel lines. Note: Replace sealing ring between fuel filter covers and line unions for fuel hoses. Tighten bolts – arrows – to 8 Nm. Fuel system, bleeding In order to ensure engine starts immediately after changing fuel filter, fuel system must be bled with diagnostic tester. Connect diagnostic tester Switch ignition on. Select “Guided Functions” . Perform vehicle identification. Diagnostic testing unit, connecting .

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ISSUE Some vehicles equipped with a 6.0L engine may exhibit a diesel odor in the cab. ACTION It may be necessary to replace the exhaust manifold gasket. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Start the engine and warm it to normal operating temperature. 2. Remove the exhaust pressure (EP) sensor. NOTE SOME BUBBLING OF MOISTURE/SOOT BETWEEN THE EXHAUST MANIFOLD AND HEAD WHEN THE ENGINE AND MANIFOLD ARE COLD IS NORMAL. ONCE THE ENGINE AND MANIFOLD ARE AT OPERATING TEMPERATURE, THEY SHOULD BE SEALED. 3. Using the Rotunda Smoke Machine (218-00001) induce smoke into the EP tube. Inspect for leaks around the exhaust manifolds and y-pipe. If a leak is found at the exhaust manifold, replace only the exhaust manifold gasket that is leaking.

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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)