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09-18-12 COOLING SYSTEM DIAGNOSTICS - OIL IN ENGINE COOLANT - 6.0L
Publication Date: September 8, 2009
FORD: 2003-2005 Excursion
2003-2007 F-Super Duty
This article supersedes TSB 07-23-14 to update the Issue Statement, Service Procedure and Part List.
Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2009 E-Series vehicles equipped with a 6.0L engine, may exhibit oil contamination into the cooling system due to an internally leaking oil cooler heat exchanger.
Follow the Service Procedure steps to correct the condition.
NOTE: ONLY USE THIS PROCEDURE IF OIL IN COOLANT IS VERIFIED, EGR COOLER WILL BE INSPECTED FOR INTERNAL LEAKS DURING OIL COOLER SERVICE.
Replace the oil cooler heat exchanger following Workshop Manual (WSM), Section 303-01 Removal and Installation, Oil Cooler, and Disassembly and Assembly, Oil Cooler, instructions.
NOTE: ENSURE THAT THE OIL RESERVOIR IS CLEAN OF ANY DEBRIS AND THAT THE SCREEN AT THE BOTTOM OF THE RESERVOIR IS NOT DAMAGED.
NOTE: LEAKING OIL COOLERS ARE FREQUENTLY CAUSED BY RESTRICTED COOLANT PASSAGES WITHIN THE OIL COOLER HEAT EXCHANGER. THESE RESTRICTIONS CAN ALSO CAUSE DAMAGE BY OVERHEATING THE EGR COOLER.
Prior to reassembly, remove and check the EGR cooler for leaks using the 2008 6.4L F-Super Duty or LCF EGR cooler block off adapters.
NOTE: A DEFECTIVE EGR COOLER CAN CAUSE COOLANT TO VENT OUT OF THE DEGAS BOTTLE AND APPEAR SIMILAR TO HEADGASKET FAILURE.
Remove the EGR cooler from the engine following WSM, Section 303-08.
Install block off adapters using standard screws and washers. (Figure 1)
Figure 1 - Article 09-18-12
Install shop air adapter and regulator and pressurize cooler to 30 psi (207 kPa). Listen for leaks.
NOTE: FOR VERY SMALL LEAKS, IT MAY BE REQUIRED THAT EGR COOLER REMAIN SUBMERGED FOR UP TO 15 MINUTES TO AID IN LEAK IDENTIFICATION. THIS TIME IS NEEDED TO ALLOW SMALL LEAKS TO DISPLACE ENOUGH WATER FROM THE COOLANT PASSAGES TO BECOME EVIDENT.
Submerge the EGR cooler horizontally in the water, with the coolant ports pointing upward. Manipulate the cooler under water to purge all trapped air from the internal coolant passages. (Figure 2)
Figure 2 - Article 09-18-12
Inspect for continuous bubbles escaping from the coolant ports.
If continuous bubbles identify a leak, replace the EGR cooler. Proceed to Step 3.
If bubbles do not identify a leak, do not replace the EGR Cooler. Install and proceed to Step 3.
Flush cooling and heater system together using the latest service procedure. Refer to other applicable articles.
Use Radiator Refiller tool to fill cooling system. Refer to WSM, Section 303-03.
Replace the degas bottle pressure cap due to oil contamination.
Change engine oil and oil filter.
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