Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

download
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.

download
The cooling system components include the: block heater (optional) cylinder head temperature sensor fan blade, fan motor and fan shroud assembly radiator pressure relief cap degas bottle radiator draincock water pump oil cooler (optional) water thermostat The water thermostat: controls the engine coolant temperature. allows quicker engine warm-up. The degas bottle: provides a location for system fill. contains coolant expansion and system pressurization. provides air separation during operation. replenishes the engine coolant to the system. The fan blade draws air through the radiator to help cool the engine coolant. The fan motor: operates only when the engine is running. will not operate when the engine is off. The engine coolant flows: from the lower radiator hose to the water pump. from the water pump to the engine block and the cylinder heads. A closed water thermostat returns the engine coolant to the water pump. An open water thermostat allows the engine coolant to flow to the radiator. Unsatisfactory coolant materials: Alcohol-type antifreeze does not provide adequate water pump lubrication. has lower boiling point reduced antifreeze protection Alkaline brine solutions will cause serious engine cooling system damage. The cylinder head temperature sensor provides a signal to the temperature gauge. will invoke failsafe cooling. The optional block heater: electrical heating element is installed in the block cooling jacket. uses a standard 110V (220V in Europe) electrical supply keeps the engine coolant warm during cold weather. The auxiliary water pump (3.9L only): provides heater coolant flow boost. has a secondary function of providing engine-off cooling. Coolant Flow 3.9L

download
The cooling system components include the: block heater (optional) cylinder head temperature sensor fan blade, fan motor and fan shroud assembly radiator pressure relief cap degas bottle radiator draincock water pump oil cooler (optional) water thermostat The water thermostat: controls the engine coolant temperature. allows quicker engine warm-up. The degas bottle: provides a location for system fill. contains coolant expansion and system pressurization. provides air separation during operation. replenishes the engine coolant to the system. The fan blade draws air through the radiator to help cool the engine coolant. The fan motor: operates only when the engine is running. will not operate when the engine is off. The engine coolant flows: from the lower radiator hose to the water pump. from the water pump to the engine block and the cylinder heads. A closed water thermostat returns the engine coolant to the water pump. An open water thermostat allows the engine coolant to flow to the radiator. Unsatisfactory coolant materials: Alcohol-type antifreeze does not provide adequate water pump lubrication. has lower boiling point reduced antifreeze protection Alkaline brine solutions will cause serious engine cooling system damage. The cylinder head temperature sensor provides a signal to the temperature gauge. will invoke failsafe cooling. The optional block heater: electrical heating element is installed in the block cooling jacket. uses a standard 110V (220V in Europe) electrical supply keeps the engine coolant warm during cold weather. The auxiliary water pump (3.9L only): provides heater coolant flow boost. has a secondary function of providing engine-off cooling. Coolant Flow 3.9L

download
All vehicles CAUTION: Suspension fasteners are critical parts because they affect the performance of vital components and systems and their failure can result in major service expense. A new part with the same part number must be installed if installation becomes necessary. Do not use a new part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. 1. Remove the upper radiator sight shield. 2. Remove the air cleaner. For additional information, refer to Section 303-12. 3. Drain the engine cooling system. For additional information, refer to Section 303-03. 4. Disconnect the upper radiator hose. 5. Disconnect the lower radiator hose. 6. Disconnect the dual flow coolant valve electrical connector and the A/C line from the fan shroud. 3.0L Engines 7. Disconnect the throttle position (TP) sensor and the idle air control (IAC) valve electrical connectors. All vehicles 8. Separate the return hose from the fan shroud and position aside. 9. Disconnect the lower radiator hose. 10. Remove the two bolts and position the multi-cooler assembly and fan shroud assembly aside. 11. Remove the front wheel and tire assemblies. For additional information, refer to Section 204-04. 12. Remove two pushpins, four bolts and both splash shields. 13. Remove the bolts and the shield. 14. NOTE: To remove the nut, first loosen the nut, then use the hex holding feature to prevent the stabilizer bar link ball joint from turning while removing the nut. Remove the nut and disconnect the stabilizer bar link (5K483). Discard the nut. 15. NOTE: To remove the nut, first loosen the nut, then use the hex holding feature to prevent the stabilizer bar link ball joint from turning while removing the nut. Remove the nut and stabilizer bar link. Discard the nut. 16. Remove and discard the nut and bolt. Disconnect the left shock absorber and spring assembly.

download
NOTE: New O-ring seals must be installed before reconnecting any A/C fitting that has been disconnected. NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system, except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. NOTE: If an evaporator core leak is suspected, the evaporator core must be vacuum leak tested before it is removed from the vehicle. 1. Recover the refrigerant. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. 2. Drain the engine cooling system. For additional information, refer to Section 303-03. 3. Remove the instrument panel. For additional information, refer to Section 501-01. 4. Remove the engine appearance cover. 5. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the 6. To install, reverse the removal procedure. Install new O-ring seals. Lubricate the refrigerant system with the correct amount of clean PAG oil. For additional information, refer to Refrigerant Oil Adding in this section. 7. Fill the engine cooling system. For additional information, refer to Section 303-03. 8. Evacuate, leak test and charge the refrigerant system. For additional information, refer to Air Conditioning (A/C) System Recovery, Evacuation and Charging in this section. Item 6: Heater Hose Clamp Removal Note 1. Detach the wiring harness bracket and position the harness aside at the dash panel.