Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD2009RV CUTAWAY 6.8 SREPAIR AND DIAGNOSISENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMDIAGNOSIS AND TESTINGENGINE COOLINGSYMPTOM CHART

2009 Ford RV Cutaway 6.8 S

Symptom Chart

2009 Ford RV Cutaway 6.8 SSECTION Symptom Chart

SYMPTOM CHART

Condition	Possible Sources	Action
Loss of coolant	Coolant hoses or tubes Hose clamps Coolant pump O-ring seal or gasket Thermostat O-ring seal or gasket Thermostat housing Radiator Transmission fluid cooler (in radiator) (may leak internally or externally) Degas bottle Pressure relief cap Coolant pump leaking from weep hole Auxiliary coolant pump (if equipped) Heater core Coolant crossover manifold assembly (if equipped) Engine gaskets (may leak internally or externally) Oil cooler (if equipped) (may leak internally or externally) Heated Throttle Body (TB) or heated TB adapter (if equipped) Heated PCV (if equipped) Cylinder block core plugs (if equipped) Cylinder head core plugs (if equipped) Block heater (if equipped) EGR cooler(s) (diesel only)	Go To PINPOINT TEST A .
The engine overheats	Low coolant level External engine coolant leak Airlock in system Pressure relief cap installation Restricted airflow through the Charge Air Cooler (CAC) (diesel only), A/C condenser or radiator Internal engine coolant leak Coolant condition/concentration Accessory drive components Non-OEM engine enhancement components Cooling fan Cooling fan clutch Radiator Thermostat Engine Coolant Temperature (ECT) indicator system (gauge) ECT sensor (if equipped) Cylinder Head Temperature (CHT) sensor (if equipped) Heater core Coolant pump Coolant flow restriction Engine oil in engine coolant	Go to PINPOINT TEST B .
The engine does not reach normal operating temperature	Low coolant level Thermostat Mechanical fan clutch always engaged Electronically actuated fan clutch ECT indicator system (gauge) ECT sensor (if equipped) CHT sensor (if equipped)	Go To PINPOINT TEST C .
The block heater does not operate correctly	Block heater power cable	CHECK continuity in all 3 power cable circuits. If any circuit measures greater than 5 ohms, INSTALL a new power cable.
The block heater does not operate correctly	Block heater	CHECK the resistance of the block heater. If the resistance does not measure between 12.5 and 17.0 ohms, INSTALL a new block heater.
The electronically controlled fan clutch does not operate correctly	Wiring Relays Fuses Fan control module Cooling fan motor(s) Cooling fan resistor(s) Electric fan clutch	REFER to the INTRODUCTION - GASOLINE MODELS article or INTRODUCTION - 6.0L DIESEL - E-SERIES article.
Noisy mechanical fan operation (if equipped)	Fan clutch	CARRY OUT the Fan Clutch Test - Minimum Speed Requirement component test.

RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

• You smell fuel, burning insulation, or see smoke.
• Brakes feel soft, pull hard to one side, or make grinding noises.
• The engine overheats, stalls repeatedly, or misfires under load.
• You are missing required tools, torque specs, or safe lifting equipment.
• You are not confident in the next step or safety outcome.