Diesel Engine - Fuel In Coolant
TSB 09-26-101/04/10
6.0L DIESEL FUEL IN ENGINE COOLANT
DIAGNOSTICS - BUILT ON OR BEFORE 9/30/2008
FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
2004-2008 E-350, E-450, E-550
This article supersedes TSB 08-23-8 to update the Service Procedure.
ISSUE
Some 2003-2007 F-Super Duty 250-750, 2003-2005 Excursion and 2004-2008 E-Series vehicles built on or before 9/30/2008 may exhibit fuel in 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 the engine coolant and not oil or combustion gases. If diesel fuel is present, refer to the following Service Procedure. If not, follow normal diagnostics and/or other applicable articles.
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.
NOTE
FAILURE TO DRAIN THE COOLING SYSTEM PRIOR TO PRESSURIZATION WILL RESULT IN AN INABILITY TO DIAGNOSE LEAK SOURCE.
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.
4. Fit the cooling system pressure tester, refer to WSM, Section 303-03. (Do not add coolant)
5. Apply 10 psi (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
FAILURE TO DRAIN THE COOLING SYSTEM PRIOR TO PRESSURIZATION WILL PREVENT BUBBLES FROM FORMING WHEN SPRAYED WITH SOAP AND WATER SOLUTION.
6. Spray a 50/50 mixture of dish soap and water generously inside each injector bore. Ensure cylinder head injector bore casting is coated with a soap layer.
7. Inspect each injector bore for bubbles. A light and mirror or bore-scope may aid in pinpointing a leak location. Most common area is between the two injector fuel sealing 0-rings in the sealing area on the side nearest the cylinder glow plug. (Figure 1)
a. Replace cylinder head if leaking through casting. Refer to WSM, Section 303-01C.
b. Flush cooling system, refer to other applicable service bulletins for proper cooling system flush procedures.
OTHER APPLICABLE ARTICLES: 08-23-01
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092601A 2003 F-Super Duty, 12.0
Excursion 6.0L: Replace Hrs.
The Right Cylinder Head,
Includes Time To Perform
Diagnosis Outlined In This
Article (Do Not Use With
Any Other Labor
Operations)
092601A 2004-2007 F-Super Duty, 12.6
2004-2005 Excursion 6.0L: Hrs.
Replace The Right
Cylinder Head, Includes
Time To Perform
Diagnosis Outlined In This
Article (Do Not Use With
Any Other Labor
Operations)
092601A 2004-2008 Econoline 6.0L: 20.0
Replace The Right Hrs.
Cylinder Head, Includes
Time To Perform
Diagnosis Outlined In This
Article (Do Not Use With
Any Other Labor
Operations)
092601B 2004-2008 Econoline 6.0L: 19.9
Replace The Left Cylinder Hrs.
Head, Includes Time To
Perform Diagnosis Outlined
In This Article (Do Not Use
With Any Other Labor
Operations)
092601B 2004-2007 F-Super Duty, 11.8
2004-2005 Excursion 6.0L: Hrs.
Replace The Left Cylinder
Head, Includes Time To
Perform Diagnosis Outlined
In This Article (Do Not Use
With Any Other Labor
Operations)
092601B 2003 F-Super Duty, 11.3
Excursion 6.0L: Replace Hrs.
The Left Cylinder Head,
Includes Time To Perform
Diagnosis Outlined In This
Article (Do Not Use With
Any Other Labor
Operations)
092601C 2003 F-Super Duty, 15.0
Excursion 6.0L: Replace Hrs.
Both Cylinder Heads,
Includes Time To Perform
Diagnosis Outlined In This
Article (Do Not Use With
Any Other Labor
Operations)
092601C 2004-2007 F-Super Duty, 15.6
2004-2005 Excursion 6.0L: Hrs.
Replace Both Cylinder
Heads, Includes Time To
Perform Diagnosis Outlined
In This Article (Do Not Use
With Any Other Labor
Operations)
092601C 2004-2008 Econoline 6.0L: 21.6
Replace Both Cylinder Hrs.
Heads, Includes Time To
Perform Diagnosis Outlined
In This Article (Do Not Use
With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
6049 01
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