Engine Cooling System -- E-Series Ford Cutaway E350 Super Duty

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Note. Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types. Failure to follow these instructions may result in cooling system or engine damage.

The cooling system components include the following

1. Block heater
2. Coolant pump
3. Cooling fan blade
4. Cooling fan clutch
5. Cooling fan shroud
6. Cooling fan stator - 6.0L diesel
7. Cylinder Head Temperature (CHT) sensor - 4.6L, 5.4L and 6.8L
8. Degas bottle
9. Engine Coolant Temperature (ECT) sensor - 6.0L diesel
10. Pressure relief cap
11. Radiator
12. Radiator draincock
13. Thermostat
14. Vistronic fan clutch - 6.0L diesel

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 distilled water.

To maintain the integrity of the coolant and the cooling system

1. Add Motorcraft Premium Gold Engine Coolant with Bittering Agent or equivalent (yellow color). Do not mix coolant types.
2. Do not add/mix orange-colored Motorcraft Specialty Orange Engine Coolant with Bittering Agent (US) Motorcraft Extended Life Engine Coolant (Canada); or equivalent. Mixing coolants may degrade the coolant's corrosion protection.
3. Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol antifreeze. These can cause engine damage from overheating or freezing.
4. Do not mix with recycled coolant. Use of such coolants may harm the engine and cooling system components. Do not mix coolant types.

Note. Inadequate concentration of Motorcraft® Diesel Cooling System Additive may result in major corrosive damage to the engine cooling system components. An excessive amount of additive may cause formation of gels that may cause coolant flow restriction, plugging of passages and overheating.

For vehicles equipped with a diesel engine, use Motorcraft® Diesel Cooling System Additive as specified in the diesel engine coolant test. Motorcraft® Diesel Cooling System Additive provides additional long-term protection against cavitation erosion and corrosion beyond that provided by the engine coolant. Check the nitrite level and freeze protection as recommended in the maintenance schedule and maintain the correct level of Motorcraft® Diesel Cooling System Additive in the cooling system. Refer to COOLANT TEST - DIESEL ENGINE .

Coolant Flow Diagram, 4.6L (2V) with Auxiliary Heat

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 1

PARTS DESCRIPTION CHART

Coolant Flow Diagram, 4.6L (2V) without Auxiliary Heat

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 2

PARTS DESCRIPTION CHART

Coolant Flow Diagram, 5.4L (2V) without Auxiliary Heat

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 3

PARTS DESCRIPTION CHART

Coolant Flow Diagram, 5.4L (2V) with Auxiliary Heat

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 4

PARTS DESCRIPTION CHART

Coolant Flow Diagram, 6.8L (2V) with Auxiliary Heat

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 5

PARTS DESCRIPTION CHART

Coolant Flow Diagram, 6.8L (2V) without Auxiliary Heat

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 6

PARTS DESCRIPTION CHART

Coolant Flow Diagram, 6.0L Diesel

Note. Black arrows indicate hot, white arrows indicate cold.

Scheme 7

PARTS DESCRIPTION CHART

Special Tool(s)

SPECIAL TOOL(S) DESCRIPTION CHART Coolant/Battery Refractometer 023-00164 or equivalent Fluke 77-IV Digital Multimeter FLU77-4 or equivalent Pressure Test Kit 014-R1072 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware or equivalent scan tool

Scheme 8

Scheme 9

Scheme 10

Material

MATERIAL SPECIFICATIONS

Principles of Operation

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley which is driven by the accessory drive belt to circulate the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine generated heat to the outside air.

The degas bottle, holds surplus coolant and removes air from the cooling system, which reduces hot spots. It also allows for coolant expansion and system pressurization, replenishes coolant to the cooling system and serves as the location for service fill.

The cooling fan draws air through the radiator to help cool the system coolant as it passes through the radiator.

The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation. The monitor will be executed once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction occurs, DTC P0125 or P0128 is set, and the malfunction indicator lamp will be illuminated.

For vehicle/engine specific information, refer to ENGINE COOLING .

Inspection and Verification

Note. The engine cooling system is filled with Motorcraft Premium Gold Engine Coolant. Mixing coolant types degrades the corrosion protection of Motorcraft Premium Gold Engine Coolant and may result in engine damage.

1. Verify the customer concern.
2. Visually check the engine coolant level at the degas bottle when the system is cold.
3. Make sure the pressure relief cap is installed correctly.
4. Record any cooling system DTCs retrieved. Refer to the «DTC CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__pcm-dtc-chart) for DTC descriptions.
5. If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved, verify the customer concern by operating the engine to duplicate the condition.
6. Inspect to determine if any of the following mechanical or electrical concerns apply. VISUAL INSPECTION CHART Mechanical Electrical Leaks or weeps at: Hoses Tubes Clamp joints Quick connect couplings (if equipped) Gaskets O-rings Thermostat housing Radiator Pressure relief cap Coolant pump Heater core (wet floor or coolant odor in vehicle) Heated Throttle Body (TB) adapter (if equipped) Coolant crossover manifold assembly (if equipped) Oil cooler (if equipped) Degas bottle Heated PCV (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) EGR cooler (diesel engine) Inoperative or damaged: Electronically actuated fan clutch Electronically actuated fan clutch controller Wiring, connectors, relays or modules Engine Coolant Temperature (ECT) sensor (if equipped) Cylinder Head Temperature (CHT) sensor (if equipped) Intake Air Temperature (IAT) sensor (if equipped) Vehicle Speed Sensor (VSS) VISUAL INSPECTION CHART Mechanical Electrical Cracked or damaged: Hoses Tubes Hose clamps Thermostat housing Radiator Pressure relief cap Cooling fan Fan clutch Coolant pump Degas bottle Oil cooler (if equipped) Coolant crossover manifold assembly (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) EGR cooler (diesel engine) Restricted airflow through the A/C condenser/radiator Drive belt loose, worn or installed incorrectly Broken or weak drive belt tensioner Excessive white or light gray exhaust smoke (may have burnt coolant odor) Coolant in engine oil Engine oil in coolant Coolant in automatic transmission fluid (if equipped) Automatic transmission fluid (if equipped) in coolant Fuel in coolant (diesel engine)
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test the system for normal operation.
8. Inspect the coolant condition. Inspect the coolant color. If Motorcraft® Premium Gold Engine Coolant has a clear or pale yellow color, this indicates higher water content than required. Test the engine coolant freezing point range with the Coolant/Battery Refractometer. The freezing point should be in the range -45°C to -23°C (-50°F to -10°F). If the vehicle is driven in cold climates less than -36°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. For 6.0L diesel, higher than normal water content will result in dilution of the additive package. Refer to «COOLANT TEST - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) and follow the procedure outlined. A pale green color indicates incorrect coolant (green in color) or Motorcraft® Diesel Cooling System Additive (VC-8) (6.0L diesel only) has been added to the system. Use of incorrect (green in color) coolant degrades the corrosion protection of Motorcraft® Premium Gold Engine Coolant. If incorrect coolant has been added, flush the system and refill with the correct mixture of distilled water and Motorcraft® Premium Gold Engine Coolant. Refer to «COOLING SYSTEM FLUSHING - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) or «COOLING SYSTEM FLUSHING - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . If Motorcraft® Diesel Cooling System Additive (VC-8) has been added, refer to «COOLANT TEST - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) and follow the procedure outlined. A red/orange color indicates incorrect coolant (red/orange in color) may have been added to the system. Use of incorrect (red/orange in color) coolant degrades the corrosion protection of Motorcraft® Premium Gold Engine Coolant. Flush the system and refill with the correct mixture of distilled water and Motorcraft® Premium Gold Engine Coolant. Refer to «COOLING SYSTEM FLUSHING - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) or «COOLING SYSTEM FLUSHING - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . NOTE: Use of commercially available stop leak products in the 6.0L Diesel may result in engine damage. NOTE: If Cooling System Stop Leak Pellets are used, darkening of the Motorcraft® Premium Gold Engine Coolant from yellow to golden tan will occur. Dark brown could indicate a commercially available stop leak may have been used and could result in loss of coolant flow to critical parts of the engine. Flush the system and refill with the correct mixture of distilled water and Motorcraft® Premium Gold Engine Coolant. Refer to «COOLING SYSTEM FLUSHING - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) or «COOLING SYSTEM FLUSHING - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . A light or reddish brown color indicates that rust may be present in the cooling system. Flush the system and refill with the correct mixture of distilled water and Motorcraft® Premium Gold Engine Coolant. Refer to «COOLING SYSTEM FLUSHING - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) or «COOLING SYSTEM FLUSHING - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . An iridescent sheen on top of the coolant could indicate a trace of oil is entering the system. For gasoline engine diagnosis, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) or for diesel engine diagnosis, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) and all appropriate TSBs that pertain to 6.0L Diesel engine cooling system concerns and follow the procedure outlined. A milky brown color may indicate that engine oil is entering the cooling system. Pressure test the cooling system. Refer to «COMPONENT TESTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . If engine oil in suspected, the cause of the leak may be internal to the engine. For gasoline engine diagnosis, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) or for diesel engine diagnosis, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) and all appropriate TSBs that pertain to 6.0L Diesel engine cooling system concerns and follow the procedure outlined. A red, orange or light green colored sheen on top of the coolant may indicate that transmission fluid is entering the cooling system. The cause may be a leaky radiator. Pressure test the cooling system. Refer to the «COMPONENT TESTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . If the engine coolant is black (diesel only), the coolant level may have been low at a previous time. The EGR cooler may have failed and exhaust gas may be contaminating the coolant. If the engine coolant appearance is acceptable, test the engine coolant freezing point range with the Coolant/Battery Refractometer. The freezing point should be in the range -45°C to -23°C (-50°F to -10°F). If the vehicle is driven in cold climates less than -36°C (-34°F), it may be necessary to increase the coolant concentration to get adequate freeze protection. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. Maximum coolant concentration is 60/40 for cold weather areas. Minimum coolant concentration is 40/60 for warm weather areas. Adjust coolant range and level if necessary: If coolant is low, add specified coolant mixture only. If the engine coolant tests too weak, remove some of the engine coolant and add undiluted engine coolant until the readings are within acceptable levels. If the engine coolant tests strong, remove some of the engine coolant and add distilled water until the readings are within acceptable levels.
9. If an obvious cause for an observed or reported concern is found, correct the cause and test the system for normal operation before proceeding to the next step.
10. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
11. If the scan tool does not communicate with the VCM : check the VCM connection to the vehicle. check the scan tool connection to the VCM . refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-communications-network-e-series) , No Power To The Scan Tool, to diagnose no power to the scan tool.
12. If the scan tool does not communicate with the vehicle: verify the ignition key is in the ON position. verify the scan tool operation with a known good vehicle. refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-communications-network-e-series) to diagnose no response from the PCM.
13. Carry out the network test. If the scan tool responds with no communication for one or more modules, refer to «MODULE COMMUNICATIONS NETWORK»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#module-communications-network-e-series) . If the network test passes, retrieve and record continuous memory DTCs.
14. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
15. If the DTCs recovered are related to the concern, go to the «PCM DTC CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__pcm-dtc-chart) . For all other DTCs, refer to «MULTIFUNCTION ELECTRONIC MODULES»(/ford/cutaway-e350-super-duty/2008-2012/remont/communication-devices/#multifunction-electronic-modules-e-series) .
16. If no DTCs related to the concern are retrieved, GO to «SYMPTOM CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__symptom-chart) .

PCM DTC Chart

PCM DTC CHART

Symptom Chart

SYMPTOM CHART

Normal Operation

The engine cooling system is a closed system that provides for coolant expansion and contraction and also changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and clamps are used to contain coolant within the cooling system and keep other fluids and contaminants from entering the cooling system.

Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.

For vehicle/engine specific information, refer to ENGINE COOLING .

This pinpoint test is intended to diagnose the following

1. Coolant hoses or tubes
2. Hose clamps
3. Thermostat O-ring seal or gasket
4. Coolant pump O-ring seal or gasket
5. Thermostat housing
6. Radiator
7. Transmission fluid cooler (in radiator)
8. Pressure relief cap
9. Coolant pump leaking from weep hole
10. Auxiliary coolant pump (if equipped)
11. Heater core
12. Heated Throttle Body (TB) adapter (if equipped)
13. Coolant crossover manifold assembly (if equipped)
14. Engine gaskets
15. Oil cooler (if equipped)
16. Degas bottle
17. Heated PCV (if equipped)
18. Cylinder block core plugs (if equipped)
19. Cylinder head core plugs (if equipped)
20. Block heater (if equipped)
21. Engine Coolant Temperature (ECT) sensor (if equipped)
22. EGR cooler(s) (diesel only)

PINPOINT TEST A: LOSS OF COOLANT

1. A1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «Inspection and Verification»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__inspection-and-verification) . Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to A2 .
2. A2 CHECK THE ENGINE COOLANT LEVEL NOTE: Allow the engine to cool before checking the engine coolant level. Ignition OFF. Visually inspect the engine coolant level at the degas bottle. Is the engine coolant level within specifications? Yes: GO to A3 . No: ADJUST the engine coolant level as necessary. GO to A3 .
3. A3 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to «COMPONENT TESTS, COOLING SYSTEM PRESSURE TEST»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__cooling-system-pressure-test) . Does the engine cooling system leak? Yes: REPAIR or INSTALL new components. TEST the system for normal operation. No: GO to A4 .
4. A4 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle for signs of engine oil or transmission fluid. Is engine oil or transmission fluid evident in the coolant? Yes: If engine oil is evident, GO to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) for engine diagnosis. If transmission fluid is evident, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate Automatic Transmission article for the procedure. TEST the system for normal operation. No: GO to A5 .
5. A5 CHECK THE ENGINE OIL AND TRANSMISSION FLUID FOR COOLANT Remove the oil level indicators from the engine and the transmission. Is coolant evident in the oil or transmission fluid? Yes: If coolant is in the engine oil, GO to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) . If coolant is in the transmission fluid, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate Automatic Transmission article for the procedure. No: GO to A6 .
6. A6 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use U-View® Combustion Leak Tester part number 560000 or equivalent. Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases. Are combustion gases present? Yes: GO to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) for engine diagnosis. No: The cooling system is operational.

The engine cooling system functions to maintain engine temperatures during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley which is driven by the accessory drive belt to circulate the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine generated heat to the outside air.

Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at the correct rate, the inability to transfer heat from the engine through the coolant (including low coolant), or an inability to transfer engine generated heat to the outside air through the radiator.

For vehicle/engine specific information, refer to ENGINE COOLING .

1. DTC P0217 Engine Coolant Over Temperature Condition
2. DTC P1285 Cylinder Head Over Temperature Condition
3. DTC P1299 Cylinder Head Over Temperature Protection Active This pinpoint test is intended to diagnose the following
4. Low coolant level
5. External engine coolant leak
6. Airlock in system
7. Pressure relief cap installation
8. Restricted airflow through the Charge Air Cooler (CAC) (diesel only), A/C condenser or radiator
9. Internal engine coolant leak
10. Coolant condition/concentration
11. Accessory drive components
12. Non-OEM engine enhancement components
13. Cooling fan blade
14. Cooling fan clutch
15. Engine Coolant Temperature (ECT) indicator system (gauge)
16. ECT sensor (if equipped)
17. CHT sensor (if equipped)
18. Heater core
19. Coolant pump
20. Coolant flow restriction

PINPOINT TEST B: THE ENGINE OVERHEATS

1. B1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «Inspection and Verification»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__inspection-and-verification) . Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to B2 .
2. B2 CHECK FOR DTCs NOTE: Refer to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) for correct scan tool hook-up procedure. Check for DTC P0217, P1285 or P1299. Is DTC P0217, P1285 or P1299 present? Yes: GO to B3 . No: Actual engine overheating has not been verified. CHECK the engine coolant temperature gauge operation. REFER to «INSTRUMENTATION, MESSAGE CENTER, AND WARNING CHIMES»(/ford/cutaway-e350-super-duty/2008-2012/remont/gauges-instrument-panels/#information-center-instrumentation-message-center-and-warning-chimes-e-series) . If any other DTCs are retrieved, REFER to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) .
3. B3 CHECK FOR AN AIRFLOW OBSTRUCTION Check the radiator or A/C condenser or CAC (diesel only) for an obstruction such as leaves or cardboard. Is an obstruction present? Yes: REMOVE the obstruction. TEST the system for normal operation. No: GO to B4 .
4. B4 CHECK THE ENGINE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant level. Ignition OFF. Visually check the engine coolant level in the degas bottle. Is the engine coolant level within specification? Yes: GO to B5 . No: ADJUST the engine coolant level as necessary. GO to B5 .
5. B5 PRESSURE TEST THE ENGINE COOLING SYSTEM Pressure test the engine cooling system. Refer to «COMPONENT TESTS, COOLING SYSTEM PRESSURE TEST»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__cooling-system-pressure-test) . Does the engine cooling system leak? Yes: REPAIR or INSTALL new components. TEST the system for normal operation. No: GO to B6 .
6. B6 CHECK THE ENGINE COOLANT FOR AN INTERNAL LEAK Inspect the engine coolant in the degas bottle for signs of engine oil or transmission fluid. Is engine oil or transmission fluid evident in the coolant? Yes: If engine oil is evident, GO to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) for gasoline engine diagnosis or «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) for diesel engine diagnosis. If transmission fluid is evident, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate Automatic Transmission article for the procedure. TEST the system for normal operation. No: GO to B7 .
7. B7 CHECK THE ENGINE OIL AND TRANSMISSION FLUID FOR COOLANT Remove the oil level indicators from the engine and the transmission. Is coolant evident in the oil or transmission fluid? Yes: If coolant is in the engine oil, GO to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) for gasoline engine diagnosis or «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) for diesel engine diagnosis. If coolant is in the transmission fluid, INSTALL a new radiator. REPAIR the transmission as necessary. Refer to the appropriate Automatic Transmission article for the procedure. No: GO to B8 .
8. B8 CHECK THE COOLING SYSTEM FOR COMBUSTION GASES NOTE: Use U-View® Combustion Leak Tester part number 560000 or equivalent. Using a cooling system combustion gas leak tester, following the instructions supplied with the tester, check the coolant for combustion gases. Are combustion gases present? Yes: GO to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) for gasoline engine diagnosis or «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-mechanical-60l-diesel-models-e-series) for diesel engine diagnosis. No: GO to B9 .
9. B9 CHECK COOLANT CONDITION Check the coolant for dirt, rust or contamination and check the coolant concentration. For vehicles with diesel engine, perform the «DIESEL ENGINE COOLANT TEST»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . Is the coolant condition OK? Yes: GO to B10 . No: For gasoline engines, FLUSH the engine cooling system. REFER to «COOLING SYSTEM FLUSHING - GASOLINE ENGINES»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . For diesel engines, CARRY OUT the recommendations of the «COOLANT TEST - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . TEST the system for normal operation.
10. B10 CHECK THE COOLING FAN OPERATION Ignition OFF. If the vehicle is equipped with a viscous fan clutch, carry out the «Fan Clutch Test»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__fan-clutch-test) in the Component Tests. If the vehicle is equipped with an electronically actuated fan clutch, refer to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) . Is the cooling fan operation OK? Yes: GO to B11 . No: INSTALL a new fan clutch. TEST the system for normal operation.
11. B11 CHECK THE COOLANT PUMP OPERATION Start the engine. Allow the engine to run for 10 minutes. Place the climate control function selector in the MAX HEAT position. Feel the heater outlet hose. Is the heater outlet hose hot? Yes: GO to B12 . No: INSTALL a new coolant pump. TEST the system for normal operation.
12. B12 CHECK THE THERMOSTAT OPERATION Start the engine. Allow the engine to run for 10 minutes. Feel the upper radiator hose. Is the upper radiator hose hot? Yes: CHECK the engine coolant temperature gauge operation. REFER to «INSTRUMENTATION, MESSAGE CENTER, AND WARNING CHIMES»(/ford/cutaway-e350-super-duty/2008-2012/remont/gauges-instrument-panels/#information-center-instrumentation-message-center-and-warning-chimes-e-series) . No: GO to B13 .
13. B13 VISUALLY INSPECT THE THERMOSTAT Carry out the «Thermostat Visual Inspection»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__thermostat-visual-inspection) . Is the thermostat damaged? Yes: INSTALL a new thermostat. TEST the system for normal operation. No: INSTALL a new thermostat. TEST the system for normal operation. If the engine still overheats, INSTALL a new radiator. TEST the system for normal operation.

The engine cooling system functions to maintain engine temperatures during operation. Correct coolant flow through the engine, radiator and remainder of cooling system passages and components is essential to maintaining a correct engine temperature.

Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. From the coolant pump, coolant is sent through the engine block and cylinder heads. A separate circuit from the engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley which is driven by the accessory drive belt to circulate the coolant. The coolant thermostat is a control valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and returns to the coolant pump. When the thermostat is opened, coolant is allowed to flow through the radiator circuit in order to transfer engine generated heat to the outside air.

Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant flow through some coolant circuits (radiator, heater core) is more than expected given the conditions, or the fan clutch is always engaged. Heat is not allowed to build in the engine because a heat exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition, perceived concerns that the engine does not reach normal operating temperature can be related to a low coolant level or trapped air which does not allow for hot coolant to be available at the heater core, an inoperative climate control system, or for concerns perceived or related to an incorrect engine temperature gauge indication.

For vehicle/engine specific information, refer to ENGINE COOLING .

1. DTC P0125 Insufficient Coolant Temperature For Closed Loop Fuel Control
2. DTC P0126 Insufficient Coolant Temperature For Stable Operation
3. DTC P0128 Coolant Thermostat (Coolant Temperature Below Thermostat Regulating Temperature) This pinpoint test is intended to diagnose the following
4. Low coolant level
5. Thermostat
6. Engine Coolant Temperature (ECT) indicator system (gauge)
7. Engine cooling fan

PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

1. C1 CARRY OUT INSPECTION AND VERIFICATION Carry out the «Inspection and Verification»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__inspection-and-verification) . Were any concerns found? Yes: REPAIR as needed. TEST the system for normal operation. No: GO to C2 .
2. C2 CHECK FOR DTC P0125, P0126 or P0128 NOTE: Refer to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) for correct scan tool hook-up procedure. Check for DTC P0125 or P0128. Is DTC P0125 or P0128 present? Yes: GO to C3 . No: The cooling system is operational. If an inoperative engine coolant temperature gauge is suspected, CHECK the engine coolant temperature gauge operation. REFER to «INSTRUMENTATION, MESSAGE CENTER, AND WARNING CHIMES»(/ford/cutaway-e350-super-duty/2008-2012/remont/gauges-instrument-panels/#information-center-instrumentation-message-center-and-warning-chimes-e-series) . If an inoperative climate control system is suspected, CHECK the climate control system operation. REFER to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(/ford/cutaway-e350-super-duty/2008-2012/remont/manual-hvac-system/#hvac-climate-control-system-general-information-and-diagnostics-e-series) . If any other DTCs are retrieved, REFER to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) .
3. C3 CHECK THE MECHANICAL COOLING FAN OPERATION Carry out the cooling fan clutch component tests. For a mechanical cooling fan clutch, refer to «COMPONENT TESTS»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . For an electronic cooling fan clutch, refer to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) . Is the cooling fan clutch OK? Yes: GO to C4 . No: INSTALL a new cooling fan clutch. TEST the system for normal operation.
4. C4 CHECK THE COOLANT LEVEL NOTE: Allow the engine to cool before checking the coolant level. Visually check the engine coolant level in the degas bottle. Is the engine coolant level within specification? Yes: INSTALL a new thermostat. TEST the system for normal operation. No: GO to «PINPOINT TEST A»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__pinpoint-test-a-loss-of-coolant) to diagnose a coolant leak.

Cooling System Pressure Test

Scheme 11

1. Turn the engine OFF.
2. Check the engine coolant level. Adjust the coolant level as necessary.
3. Attach the Radiator/Heater Core Pressure Tester from the Pressure Test Kit to the degas bottle nipple and overflow hose. Install a pressure test pump to the quick-connect fitting of the test adapter.
4. Slowly depress the plunger of the pressure test pump until the pressure gauge reading stops increasing and note the highest pressure reading obtained. If the pressure reading exceeds the maximum cap pressure listed in the specifications table, install a new pressure relief cap.
5. If the system does not hold pressure, remove the pressure relief cap and wash in clean water to dislodge all the foreign material from the gasket. Check the sealing surface in the filler neck of the degas bottle for nicks or cuts. Install the pressure relief cap.
6. Pressurize the engine cooling system as described in Step 4 above. Observe the gauge reading for approximately 2 minutes. Pressure should not drop during this time. If the pressure drops within this time, inspect for leaks and repair as necessary.
7. If no leaks are found and the pressure drops. the pressure relief cap may be leaking. Install a new pressure relief cap and retest the system.
8. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may be internal to the radiator transmission cooler. Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as necessary.
9. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to «ENGINE SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/mechanical/#engine-system-general-information-e-series) to diagnose the engine.
10. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust as necessary.

Thermostat

A new thermostat should be installed only after the following tests and checks have been carried out

1. Pinpoint Test A, B or C
2. Thermostat Visual Inspection

Thermostat Visual Inspection

1. Remove the thermostat.
2. Examine the thermostat for signs of damage including: Valve not fully seated (light visible through the valve) Foreign material lodged in the main valve Bent or broken frame or flange Bent or broken spring Bent or broken valve or valve stem Wax leaking from wax reservoir or a bulge in the reservoir Any other damage or distortion
3. If damage is found during the inspection, remove any foreign material or broken pieces and install a new thermostat.
4. If no damage is found during the inspection, continue troubleshooting the system concern. Go to the «SYMPTOM CHART»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__symptom-chart) for further instructions.

Radiator Leak Test, Removed From Vehicle

Note. Never leak test an aluminum radiator in the same water that copper/brass radiators are tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum radiators.

Note. Always install plugs in the oil cooler fittings before leak testing or cleaning any radiator.

Note. Clean the radiator before leak testing to avoid contamination of tank.

1. Leak test the radiator in clean water with pressurized air to the maximum pressure listed in the specifications.

Fan Clutch Test

1. Turn the engine OFF and wait until the fan comes to a complete stop.
2. Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked. For an electronically actuated fan clutch, refer to the «INTRODUCTION - GASOLINE MODELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/testing-diagnostics/#engine-controls-introduction-except-diesel-hybrid) . For a viscous fan clutch, carry out the following

Fan Clutch Test - Minimum Speed Requirement

1. Use a suitable marker to mark the coolant pump or fan pulley and one of the fan blades.
2. Make sure the A/C is OFF, if equipped.
3. Start the engine and run it at approximately 2,000 rpm for 5 minutes or until there is a noticeable reduction in fan noise to allow the fan clutch to go into disengaged mode.
4. Aim a laser photo tachometer at the coolant pump or fan pulley. Run the engine to achieve 3,000 rpm at the coolant pump or fan pulley.
5. With the coolant pump or fan pulley at 3,000 rpm, aim the laser photo tachometer at the fan blade. Monitor and record fan speed.
6. The fan blade speed must be less than the specified rpm at 3,000 rpm coolant pump or fan pulley rpm. Refer to the «SPECIFICATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) for correct fan speed.
7. Turn the engine off.
8. If the fan blade speed was greater than specified, install a new fan clutch.

Fan Clutch Test - Maximum Speed Requirement

1. Use a suitable marker to mark the coolant pump or fan pulley and one of the fan blades.
2. Block off areas on each side of the radiator in the engine compartment, the front of the radiator grille and the bumper. Close the hood. This will raise the temperature of the air striking the fan clutch and should cause the fan blade to operate at maximum speed.
3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position, if equipped.
4. Start the engine and run it at approximately 2,000 rpm until normal operating temperature has been achieved. Using an infrared thermometer, monitor the coolant pump or fan pulley. Run the engine until the coolant pump or fan pulley is at least 96°C (205°F).
5. Aim a laser photo tachometer at the coolant pump or fan pulley. Run the engine to achieve 3,000 rpm at the coolant pump or fan pulley.
6. With the coolant pump or fan pulley at 3,000 rpm, aim the laser photo tachometer at the fan blade. Monitor and record fan blade speed.
7. The fan blade speed must be greater than the specified rpm at 3,000 rpm coolant pump or fan pulley rpm. Refer to the «SPECIFICATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) for correct fan speed.
8. Open the hood and allow the engine to idle momentarily to lower engine temperature. Turn the engine off and remove the blocks from the radiator, grille and bumper.
9. If the fan blade speed is less than specified, install a new fan clutch.

SPECIAL TOOL(S) DESCRIPTION CHART 3-Way HD Antifreeze Coolant Test Kit 328-00001 or equivalent

Scheme 12

MATERIAL SPECIFICATIONS

Scheme 13

1. Inspect the coolant condition. If the coolant is clean and a normal color, proceed with the test. If the coolant is dirty or an unusual color, refer to «INSPECTION AND VERIFICATION»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series__inspection-and-verification) in Diagnosis and Testing.
2. Start with clean, dry hands and tools.
3. Collect a coolant sample from the degas bottle using the syringe or drain from the radiator draincock.
4. Remove one test strip from the bottle.
5. Dip the strip in the coolant sample for one second, remove and shake the strip briskly to remove the excess. Wait 45 seconds, but no longer than 75 seconds, after dipping the strip to compare and record the results.
6. Check the strip and record the results. Compare the freeze point (end pad) to the color chart on the bottle and record the results. Compare the nitrite test (end closest to the handle) to the color chart on the bottle and record the results. The middle pad is for molybdate which is not a performance measurement used in determining maintenance requirements for these applications.
7. Check the nitrite levels. If the nitrite level exceeds 800 parts per million, anticorrosion strength meets specifications, no action is required. If the nitrite level is between 300 parts per million and 800 parts per million, anticorrosion strength is low. Add one bottle of Motorcraft® Diesel Cooling System Additive. If nitrite level is below 300 parts per million, anticorrosion strength is very low and cannot be restored. Proceed to step 9 .
8. Verify that the freeze point is appropriate for the climate. If the coolant tests weak, remove some of the coolant and add undiluted engine coolant until the readings are within acceptable levels. If the coolant tests strong, remove some of the coolant and add distilled water until the readings are within acceptable levels.
9. Flush the cooling system. For additional information, refer to «COOLING SYSTEM FLUSHING - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART RADIATOR REFILLER 078-00592

Scheme 14

MATERIAL SPECIFICATIONS

Draining

Note. Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types. Failure to follow these instructions may result in cooling system or engine damage.

Note. The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be disposed of correctly. Failure to follow these instructions may result in cooling system or engine damage.

Note. Less than 80% of coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement.

1. Release the pressure in the cooling system in the following sequence. Make sure the engine is cool. Wrap a thick cloth around the coolant pressure relief cap on the degas bottle. Slowly turn the cap counterclockwise (left) until the pressure begins to release. Step back while the pressure releases. When you are sure all the pressure has been released, use the cloth to turn and remove the cap.
2. Place a suitable container below the radiator draincock.
3. Open the radiator draincock and drain the coolant into a suitable container.
4. Close the radiator draincock when finished.

Scheme 15

1. Install the RADIATOR REFILLER and follow the RADIATOR REFILLER manufacturer's instructions to fill and bleed the cooling system. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. Maximum coolant concentration is 60/40 for cold weather areas. Minimum coolant concentration is 40/60 for warm weather areas.

Filling without RADIATOR REFILLER

1. Add the correct engine coolant mixture to the degas bottle. Recommended coolant concentration is 50/50 ethylene glycol to distilled water. Maximum coolant concentration is 60/40 for cold weather areas. Minimum coolant concentration is 40/60 for warm weather areas.
2. Move the temperature blend selector to the full warm position.
3. Run the engine until it reaches operating temperature.
4. Add the correct engine coolant mixture to the degas bottle until the coolant level is between the COOLANT FILL LEVEL marks.
5. Turn off the engine and allow the cooling system to cool.
6. Repeat Steps 1 through 5 until the degas bottle level is OK.

Bleeding without RADIATOR REFILLER

1. Select the maximum heater temperature and medium low blower motor speed settings. Position the control to discharge air at the panel vents in the instrument panel.
2. Start the engine and allow to idle. While the engine is idling, feel for hot air at the panel vents.
3. Start engine and allow to idle until normal operating temperature is reached. Hot air should discharge from the panel vents. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch.
4. Shut the engine off and allow to cool.
5. Check the engine for coolant leaks.
6. Check the engine coolant level in degas bottle and fill as necessary.

SPECIAL TOOL(S) DESCRIPTION CHART Drain Kit 164-R3662 or equivalent Flush Kit Hardware Package 164-R3658 or equivalent Proflush and Fill Coolant Flush and Fill 023-00154 or equivalent

Scheme 16

Scheme 17

MATERIAL SPECIFICATIONS

1. Once pressure is released, remove the pressure relief cap. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Remove the thermostat. For additonal information, refer to «THERMOSTAT - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) or «THERMOSTAT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Install the coolant hose connection without the thermostat.
4. Use cooling system Flush-All, Flush Kit Hardware Package and Drain Kit to flush the engine and radiator. Use Premium Cooling System Flush VC-1 or equivalent meeting Ford specification ESR-M14P7A.
5. Install the thermostat. For additional information, refer to «THERMOSTAT - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) or «THERMOSTAT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
6. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

MATERIAL SPECIFICATIONS

Note. This procedure should be used to clean and flush the diesel cooling system to make sure that all rust is removed from the system. Failure to follow these instructions may result in engine damage.

Note. If oil or fuel is present in the cooling system, refer to the appropriate Technical Service Bulletins (TSBs) that pertain to 6.0L diesel engine cooling system concerns and follow the procedure outlined. Failure to remove all contaminants from the cooling system may result in engine damage.

Scheme 18

Scheme 19

Scheme 20

1. Once pressure is released, remove the pressure relief cap. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Remove the thermostat housing assembly. For additional information, refer to «THERMOSTAT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Position the thermostat housing assembly in the vise. Press down on the thermostat crossbar and rotate the thermostat to remove it from the thermostat housing assembly.
4. Install the thermostat housing without the thermostat. For additional information, refer to «THERMOSTAT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
5. Remove the LH cylinder block drain plug and drain the cylinder block of coolant.
6. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in).
7. Fill the cooling system with water and 1.89L (2 qt) of Motorcraft® Engine Cooling System Iron Cleaner (VC-9).
8. Using the scan tool, use the active command and set the engine rpm to 1,175. Run the engine for one hour.
9. Once pressure is released, remove the pressure relief cap. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) . Leave the radiator draincock open.
10. Remove the LH cylinder block drain plug.
11. Remove the starter. For additional information, refer to «STARTING SYSTEM - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) .
12. Remove the RH cylinder block drain plug.
13. Flush the cooling system with clean water through the degas bottle to completely remove the Motorcraft® Engine Cooling System Iron Cleaner (VC-9) from the cooling system. Flush the cooling system with clean water until no foam or discoloration is draining from the cooling system.
14. Backflush the heater core. For additional information, refer to «HEATER CORE BACKFLUSHING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
15. Flush the cooling system with clean water through the degas bottle to completely remove the Motorcraft® Engine Cooling System Iron Cleaner (VC-9) from the cooling system. Flush the cooling system with clean water until no foam or discoloration is draining from the cooling system.
16. Close the radiator draincock.
17. Install the thermostat. For additional information, refer to «THERMOSTAT - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
18. Install the RH cylinder block drain plug. Tighten to 20 Nm (177 lb-in).
19. Install the starter. For additional information, refer to «STARTING SYSTEM - DIESEL ENGINE»(/ford/cutaway-e350-super-duty/2008-2012/remont/starter/#starting-system-diesel-models-e-series) .
20. Install the LH cylinder block drain plug. Tighten to 20 Nm (177 lb-in).
21. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

SPECIAL TOOL(S) DESCRIPTION CHART Flush Kit Hardware Package 164-R3658 or equivalent Drain Kit 164-R3662 or equivalent

1. Once pressure is released, remove the pressure relief cap.
2. Partially drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Use an appropriate cooling system flusher to backflush the heater core. Use Premium Cooling System Flush VC-1 or equivalent meeting Ford specification ESR-M14P7-A.
4. Fill the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

Scheme 21

PARTS DESCRIPTION CHART

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Loosen the block heater retaining screw and remove the block heater. To install, tighten to 2 Nm (18 lb-in).
4. To install, reverse the removal procedure.

Scheme 22

PARTS DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Drain the cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. Remove the engine cover. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350-super-duty/2008-2012/remont/exterior-body-panels/#body-panel-system-front-end-body-panels-e-series) .
4. Disconnect the block heater electrical connector.
5. Remove the block heater and discard the O-ring seal. To install, tighten to 41 Nm (30 lb-ft).
6. To install, reverse the removal procedure. Install a new O-ring seal.

MATERIAL SPECIFICATIONS

Scheme 23

PARTS DESCRIPTION CHART

1. Drain the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(/ford/cutaway-e350-super-duty/2008-2012/remont/removal-installation/#intake-air-distribution-system-intake-air-filtering-system-e-series) .
3. If servicing the thermostat housing, disconnect the upper radiator hose.
4. Remove the 2 bolts and position the thermostat housing aside. Remove the thermostat and discard the O-ring seal. Inspect and clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Install a new O-ring seal. To install, tighten to 25 Nm (18 lb-ft).
5. To install, reverse the removal procedure.
6. Fill and bleed the engine cooling system. For additional information, refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

Scheme 24

PARTS DESCRIPTION CHART

MATERIAL SPECIFICATIONS

Scheme 25

PARTS DESCRIPTION CHART

Scheme 26

1. Remove the fan and fan clutch. For additional information, refer to «COOLING FAN - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Loosen the 4 coolant pump pulley bolts.
3. Rotate the tensioner clockwise and remove the accessory drive belt from the coolant pulley.
4. Remove the 4 bolts and the coolant pump pulley.
5. Remove the 4 coolant pump bolts and the coolant pump. Discard the coolant pump O-ring seal. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.

Installation

1. Install a new O-ring on the coolant pump.
2. Position the coolant pump and install the 4 bolts. Tighten to 25 Nm (18 lb-ft).
3. Position the coolant pump pulley onto the coolant pump and install the bolts finger-tight.
4. Rotate the tensioner clockwise and install the accessory drive belt onto the coolant pulley.
5. Tighten the coolant pump pulley bolts. Tighten to 25 Nm (18 lb-ft).
6. Install the fan and fan clutch. For additional information, refer to «COOLING FAN - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

MATERIAL SPECIFICATIONS

Scheme 27

PARTS DESCRIPTION CHART

Scheme 28

1. Remove the cooling fan stator. For additional information, refer to «COOLING FAN STATOR - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Loosen the 4 coolant pump pulley bolts.
3. Rotate the drive belt tensioner clockwise and remove the accessory drive belt from the coolant pump pulley.
4. Remove the 4 bolts and the coolant pump pulley.
5. Remove the 4 bolts and the coolant pump. Discard the O-ring seal.
6. Clean and inspect the coolant pump sealing surfaces with metal surface prep.

1. Install a new O-ring on the coolant pump.
2. Position the coolant pump and install the 4 bolts. Tighten to 23 Nm (17 lb-ft).
3. Position the coolant pump pulley and install the 4 bolts finger-tight.
4. Rotate the drive belt tensioner clockwise and install the accessory drive belt onto the coolant pump pulley.
5. Tighten the 4 coolant pump pulley bolts. Tighten to 31 Nm (23 lb-ft).
6. Install the cooling fan stator. For additional information, refer to «COOLING FAN STATOR - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

Scheme 29

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

SPECIAL TOOL(S) DESCRIPTION CHART Holding Wrench, Fan Clutch Pulley (4.6L, 5.4L) 303-239 (T84T-6312-C) Holding Wrench, Fan Clutch Pulley (6.8L) 303-478 (94T-6312-AH) Wrench, Fan Clutch Hub Nut (4.6L, 5.4L) 303-240 (T84T-6312-D) Wrench, Fan Clutch Hub Nut (6.8L) 303-214 (T83T-6312-B)

Scheme 30

Scheme 31

Scheme 32

Removal

All vehicles

Note. The fan, fan clutch and shroud must be removed and installed together due to insufficient clearance to remove them separately.

All vehicles

Scheme 33

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350-super-duty/2008-2012/remont/hoistjack/#jacking-lifting-e-series) .
2. Remove the cooling fan. For additional information, refer to «COOLING FAN - 4.6L, 5.4L AND 6.8L»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
3. If equipped, remove the underbody splash shield.
4. Disconnect the transmission oil cooler hoses. Plug or cap the lines as needed.
5. Disconnect the lower radiator hose.
6. Remove the 4 bolts and the 2 radiator support brackets. To install, tighten to 20 Nm (177 lb-in).
7. Remove the radiator from the vehicle.
8. To install, reverse the removal procedure. If necessary, install new appropriately sized worm drive-type clamps.

Scheme 34

PARTS DESCRIPTION CHART

Scheme 35

PARTS DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

SPECIAL TOOL(S) DESCRIPTION CHART Wrench, Fan Clutch Nut 303-591

Scheme 36

Scheme 37

Scheme 38

1. Remove the radiator. For additional information, refer to «RADIATOR - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .
2. Disconnect the electrical connector. Release the wiring from the stator.
3. Remove the 4 cooling fan stator bolts. To install, tighten to 30 Nm (22 lb-ft).
4. Using the Fan Clutch Nut Wrench, loosen the fan clutch by turning the wrench counterclockwise. Remove the cooling fan, clutch and stator. To install, tighten to 180 Nm (133 lb-ft).
5. If servicing the fan blade assembly or clutch, remove the 6 bolts and separate the cooling fan from the clutch. To install, tighten to 20 Nm (177 lb-in).
6. To install, reverse the removal procedure.

1. For additional information, refer to «COOLING FAN - 6.0L DIESEL»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) .

Scheme 39

Scheme 40

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. Using hose clamp pliers, clamp the lower degas bottle hose.
3. Using a suitable suction device, siphon the coolant from the degas bottle.
4. Disconnect the upper coolant hoses at the degas bottle.
5. Remove the bolts and position out the degas bottle. To install, tighten to 6 Nm (53 lb-in).
6. Disconnect the lower degas bottle coolant hose and remove the degas bottle.
7. To install, reverse the removal procedure.
8. Fill the degas bottle. Refer to «COOLING SYSTEM DRAINING, FILLING AND BLEEDING»(/ford/cutaway-e350-super-duty/2008-2012/remont/cooling-system-mechanical/#engine-cooling-system-e-series) for the recommended coolant mixture and fill level.

Disassembly and Assembly

See also:
• INTRODUCTION - GASOLINE MODELS
• ENGINE SYSTEM - GENERAL INFORMATION
• ENGINE - 6.0L DIESEL
• MODULE COMMUNICATIONS NETWORK
• MULTIFUNCTION ELECTRONIC MODULES
• INSTRUMENTATION, MESSAGE CENTER, AND WARNING CHIMES
• CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
• STARTING SYSTEM - DIESEL ENGINE
• JACKING & LIFTING
• FRONT END BODY PANELS
• INTAKE AIR DISTRIBUTION & FILTERING
• COOLANT TEST - DIESEL ENGINE
• DTC CHART
• SYMPTOM CHART
• PINPOINT TEST C
• PINPOINT TEST B
• PINPOINT TEST A
• FAN CLUTCH TEST - Minimum Speed Requirement
• Inspection and Verification
• COMPONENT TESTS, COOLING SYSTEM PRESSURE TEST
• Fan Clutch Test
• Thermostat Visual Inspection
• DISASSEMBLY AND ASSEMBLY