Diesel Data: Automotive Repair

Cooling System - Coolant Leak Into Spark Plug Wells

TSB 10-19-5

10/11/10

COOLANT LEAK IN SPARK PLUG WELL - ENGINE
MISFIRE

FORD:
2011 Fiesta

ISSUE
Some 2011 Fiesta vehicles may experience a coolant leak from the cup plug in the spark plug well area. The vehicle may exhibit coolant leak from the valve cover breather orifice located on the back center of the valve cover behind spark plug boot number 4 with or without symptoms and may also experience an engine misfire with diagnostic trouble codes (DTCs) stored in PCM memory due to the coolant leak in the spark plug well area.

ACTION
Follow the Service Procedure to correct the concern.

SERVICE PROCEDURE

1. Remove spark plugs boots 2 and 3 and inspect both plug wells for presence of engine coolant.

a. If coolant is present, proceed to Step 2.

b. If coolant is not present, do not continue with this procedure. Refer to normal diagnostics in the Powertrain Control/Emissions Diagnosis (PC/ED) or Workshop Manual (WSM).

2. Remove the valve cover. Refer to WSM, Section 303-01.

3. Drain the coolant system. Refer to WSM, Section 303-03.

4. Apply grease to the cup plug(s). This will keep the metal shavings from entering the coolant system.

5. Drill a small pilot hole in the cup plug.

6. Using a suitable slide hammer with a sheet metal screw, remove the cup plug(s).

7. Clean off the cylinder head holes with Isopropyl Alcohol to remove any the remaining sealant.

8. Use Motorcraft(R) Threadlock 262 on the walls of the head and on the cup plugs before installation.





9. Install the new cup plug(s) using a suitable tool such as Snap-On(R) 2009 FPI Kit, Freeze Plug Installer or equivalent. Installation depth should be between the top of, or up to 1/32" (1 mm) below bottom cut in the flange of the cup plug hole. (Figure 1)

a. Allow the sealant to cure for 30 minutes.

10. Install the valve cover. Refer to WSM, Section 303-01.

11. Refill the Cooling System. Refer to WSM, Section 303-03.

12. Inspect spark plug wires 2 & 3.

13. If coolant is observed on wire 2, replace spark plugs and wires for cylinders 1 and 2.

14. If coolant is observed on wire 3, replace spark plugs and wires for cylinders 3 and 4.





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

101905A 2011 Fiesta: Replace Cup 1.3 Hrs.
Plugs, Includes Time To
Replace Spark Plugs And
Spark Plug Wires As
Necessary (Do Not Use
With Any Other Labor
Operations)

DEALER CODING
CONDITION
BASIC PART NO. CODE
6049 12





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