6.0L POWER STROKE

Ford 6.0L POWER STROKE Service Procedures And General Diagnostics

Ford 6.0L POWER STROKE

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''F'' Series

Super Duty

Table of Contents

Safety Notice2
Table of Contents4
6.0L Power Stroke6
- Power Stroke Overview7
- Engine Features7
- Horsepower & Torque Chart7
- 6.0L Power Stroke Diesel Specifications8
- Engine Serial Number9
- Serial Number/Ficm Calibration Label9
- Emissions Label9
- Left Front of Engine10
- Front of Engine10
C O M P O N E N T L O C at I O N S10
- Rear of Engine12
- Right Rear of Engine12
- Right Side of Engine13
- Right Front of Engine13
- Top of Engine14
- Rocker Carrier15
- Cylinder Head15
- Rear Geartrain15
Features15
- Dual Mass Flywheel16
- Normal Heat Treatment Discoloration16
- Single Mass Flywheel16
- Cooling System Features18
- Cooling System Flow18
C O O L I N G S y S T E18
- Cooling System Flow: Front Cover19
- Cooling System Flow: Back of Front Cover19
- Cooling System Flow: Oil Cooler19
- Injector Sleeve20
- Cooling System Flow: EGR Cooler20
Water Pump & Front Cover20
- Glow Plug Sleeve21
- Coolant Recovery Bottle21
- Lubrication System Features22
L U B R I C a T I O N S y S T E22
System Flow22
- Lubrication System Oil Flow23
- Lube Pressure Oil System Schematic23
- Oil Pan / Bed Plate23
- Oil Pressure Regulator24
- Gerotor Oil Pump24
- Pick-Up Tube / Oil Aeration24
- Oil Pick-Up Tube24
- Front Cover25
- Oil Cooler25
- Oil Cooler Housing & Filter Base25
- Oil Filter Base & Valves26
- Oil Filter26
- Oil Reservoir & Screen26
- Oil Temperature Sensor26
- Oil Pressure Switch26
- Turbocharger Oil Drain Tube27
- Turbocharger Oil Supply & VGT Control27
- Oil Flow at Oil Reservoir27
- Engine Fuel System Flow28
F U E L S U P P L y S y S T E28
- Engine Fuel Flow29
- HFCM (Horizontal Fuel Conditioning Module)30
- HFCM (Horizontal Fuel Conditioning Module) Fuel Flow30
- Engine Mounted Fuel Filter31
- Fuel Pressure Regulator31
- Fuel Inlet Check Valves31
- Air Management System Features32
- Air Management System Flow32
System Flow33
A I R M a N a G E M E N T S y S T E33
Vgt33
- Air Filter / Filter Minder34
- Air Filter Element34
- Charge Air Cooler34
- VGT Features35
- VGT Compressor35
- VGT Turbine35
- VGT Control Valve36
- VGTCV Flows36
- VGT Turbine Vanes Open37
- VGT Turbine Vanes Partially Closed37
- VGT Turbine Vanes Closed37
- EGR Valve38
- EGR Flow38
- EGR Cooler38
- EGR Throttle39
- Intake Manifold39
- Generation II Fuel Management System Diagram40
- Generation II Fuel Management System Major Components40
- Generation II Fuel Management System Advantages40
F U E L M a N a G E M E N T S y S T E40
- High Pressure Oil System Flow41
- High Pressure Oil System Schematic42
- High Pressure Pump & Cover43
- IPR (Injection Control Pressure Regulator) & ICP (Injection Control Pressure Sensor)43
- High Pressure Oil Rail with AWA Feature43
- Fuel Injector Features44
- Injector & O-Rings44
- Injector Coils & Spool Valve44
- Intensifier Piston45
- Plunger & Barrel45
- Injection Nozzle45
- Fill Cycle46
- Three Stages of Injection46
Stages of Injection46
- End of Main Injection Step 148
- End of Main Injection Step 248
- Electrical Components50
- Sensors Overview50
E L E C T R I C a L C O M P O N E N T50
- AP (Accelerator Pedal Position)51
- Baro (Barometric Pressure)52
- CKP (Crankshaft Position)53
- CMP (Camshaft Position)54
- ECT (Engine Coolant Temp.)55
- EGRVP (Exhaust Gas Recirculation Valve Position)56
- EOP (Engine Oil Pressure Switch)57
- EOT (Engine Oil Temperature)58
- EP (Exhaust Pressure)59
- IAT1 (Intake Air Temperature)60
- ICP (Injection Control Pressure)62
- MAF (Mass Air Flow)63
- MAP (Manifold Absolute Pressure)64
- IPR (Injection Pressure Regulator)65
- EGR (Exhaust Gas Recirculation) Valve65
Actuators65
- FICM (Fuel Injection Control Module)66
- VGTCV (Variable Geometry Turbocharger Control Valve)66
Other Electrical Components66
- PCM (Powertrain Control Module)67
- Glow Plug System67
- GPCM (Glow Plug Control Module)67
- Glow Plug68
- Glow Plug Buss Bar68
- Glow Plug System Diagnostics69
- Oil Filter: Replacement70
- Fuel Filter: Replacement70
- Injector: Removal70
U N I Q U E S E R V I C E P R O C E D U R E70
- Injector O-Ring: Replacement71
- Injector Installation72
- Cylinder Head - Rocker Carrier: Removal73
- Rocker Arms / Bridges73
- Cylinder Head - Rocker Fulcrums73
- Glow Plug / Injector Sleeve: Removal74
- Glow Plug / Injector Sleeve: Installation74
- EGR Valve: Removal74
- Crankcase Ventilation: Removal / Oil Carryover75
- Turbocharger Oil Supply: Removal75
- EGR Cooler: Removal & Installation75
- Turbocharger Oil Drain Tube: Removal76
- IPR Valve: Removal76
- High Pressure Pump Cover: Removal77
- Front Cover: Removal77
- Front Cover: Dowel Locations77
- Front Cover: Gerotor Oil Pump78
- Front Cover: Sealant Application78
- Glow Plug / Buss Bar: Removal78
- Crankshaft Rear Seal Dust Cover79
- Crankshaft Primary Flange79
- High Boost/High EP at WOT no Load80
- Air in Fuel80
G E N E R a L D I a G N O S T I C80
- ICP Pressure Low During Crank81
- Power or Ground Issues81
- Injector I/O Test81
- Cylinder Balance Test82
- Relative Compression Test82
- Oil Aeration Test82
- Glow Plug82
- Crankcase Pressure Test83
- Injector Buzz/No Buzz83
Appendix84
- Special Torque Chart85
- T O R Q U E C H a R T85
- H a R D S T a R T / N O S T a R T D I a G N O S T I C89
- Hard Start/No Start Diagnostics89
- P E R F O R M a N C E D I a G N O S T I C90
  - Performance Diagnostics90
  - Wiring Diagram91
- D I a G N O S T I C C O D E95
- Diagnostic Codes95
- G L O S S a R98
- Index101
- N O T E104

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Ford 6.0L POWER STROKE Specifications

General

Brand	Ford
Model	6.0L POWER STROKE
Category	Engine
Language	English

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