| 2003 - 2007 (ALL MODEL YEARS) |
| COMMON PROBLEM/FAILURE: | CAUSE: | SOLUTION: | PART NUMBER: |
| EGR valve sticking ('03 to early '04) | Carbon, soot buildup | Replace or clean EGR valve | PN 4C3Z-9F452-A |
| EGR valve sticking (late '04 to '07) | Carbon, soot buildup | Replace or clean EGR valve | PN 53Z-9F452-AA |
| Blown head gasket | Head bolts stretch | ARP head studs, H-11 head studs | PN 250-4202 (ARP)
PN1300-5001 (Elite) |
| Oil cooler | Plugged or gasket failure | Clean oil cooler and/or replace gasket | PN 3C3Z-6A642-AA |
| Sticking spool valve in injector | Stuck spool valve (open/closed) | Inductive Heating Flash - FICM | PN Need VIN |
| Cracked IC boot ('03 to early '04) | Wear, heat | Replace boot | PN 6C3Z-6C640C |
| Cracked IC boot (late '04 to '07) | Wear, heat | Replace boot | PN 6C3Z-6C640A |
| Coolant leak | Degas bottles crack on seams | Replace degas bottle | PN 6C3Z-8A-O8OB |
| FICM calibration(s) | Bad calibration, fried circuit board | Re-flash or new FICM | PN Need VIN |
| Injector harness wear | Chafed wiring harness | Replace wiring harness (by application) | PN Need VIN |
| FICM harness wear | Chafed wiring harness | Replace wiring harness (by application) | PN Need VIN |
Glossary
EGR: Exhaust Gas Recirculation
IC: Intercooler
FICM: Fuel Injection Control Module
ICP: Injection Control Pressure
HPOP: High Pressure Oil Pump
VGT: Variable Geometry Turbo