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Ford 6.0L Power Stroke Manual
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Ford 6.0L Power Stroke Manual

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All rights reserved. Reproduction by any means, electronic or mechanical
including photocopying, recording or by any information storage and retrieval
system or translation in whole or part is not permitted without written
authorization from Ford Motor Company. Ford may change the contents without
notice and without incurring obligation.
Copyright © 2003 Ford Motor Company

Table of Contents

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Summary of Contents for Ford 6.0L Power Stroke

  • Page 1: Table Of Contents

    Ford Motor Company. Ford may change the contents without notice and without incurring obligation. Copyright © 2003 Ford Motor Company...

  • Page 2: Introduction

    This guide will acquaint you with the 6.0L Power Stroke diesel engine. It provides recommendations on engine care and operating procedures. For complete vehicle information, also refer to the Owner’s Guide included with the vehicle.
  • Page 3 Introduction overpressurization and the risk of fuel expulsion and fires. To determine whether the vehicle is equipped with the Ford ambulance preparation package, inspect the information plate on the driver’s side door pillar. Contact the manufacturer of your vehicle to determine whether the ambulance manufacturer’s followed Ford’s recommendations.
  • Page 4 Introduction The FCM/HFCM should be drained at regular intervals or when the WATER IN FUEL light illuminates in the instrument cluster. The fuel injectors are located in the center of the combustion chambers in the cylinder head between the rocker arm assemblies. The glow plug system and fuel injection system are controlled through the Powertrain Control Module (PCM) and Fuel Injection Control Module (FICM).
  • Page 5 Introduction Engine cooling system The cooling system contains an engine oil cooler which is mounted in the center valley of the engine. The cooler’s function is to regulate engine oil temperature. Engine governed speed The engine governor is controlled by the PCM. The PCM controls fuel input to limit maximum engine speed.

  • Page 6: Instrumentation

    Instrumentation Instrumentation E-SERIES EXCURSION & F-SUPER DUTY (EXCEPT HARLEY-DAVIDSON) RPMX1000 SELECT KM/H RESET HAUL P R N 3 2 1 DIESEL FUEL ONLY F-SUPER DUTY HARLEY-DAVIDSON...
  • Page 7 Instrumentation Glow plug pre-heat indicator With the key in the ON position, light will illuminate if glow plug heat is necessary as a starting aid. Wait until the light goes off before starting. The light should always illuminate briefly, when the ignition key is in the ON position.
  • Page 8 Instrumentation Engine air filter The engine air filter warning light illuminates when the air filter restriction gauge reaches the CHANGE FILTER mark. The condition should be verified by inspecting the underhood air filter restriction gauge; the warning light is only a secondary indicator. Always use the underhood air filter restriction gauge to determine when the air filter element needs to be changed.
  • Page 9 Instrumentation Air filter restriction gauge (if equipped) The restriction gauge, located on the upper housing of the air cleaner assembly, monitors the condition of the air filter element in two ways: • First, the colored indictor inside the gauge highlights the percentage that the air filter element is clogged with dust or CHANGE FILTER...
  • Page 10 Instrumentation The air filter element must be replaced when the colored band on the gauge reaches the CHANGE FILTER mark. Engine performance and fuel economy are adversely affected when the maximum restriction is reached. Blowing-out the air filter CHANGE FILTER element with compressed air is not recommended as the compressed air may damage the...
  • Page 11 Instrumentation After servicing the air filter element, reset the restriction gauge by pressing the button on the end of the gauge. Note: If the vehicle is operated in a heavy snow storm, in blowing snow or the vehicle is equipped with a snowplow, the engine air filter element may become partially clogged with snow and/or ice.

  • Page 12: Driving

    Driving Driving STARTING THE ENGINE Read all starting instructions carefully before you start your vehicle. For temperatures below 0°C (32°F), the use of the correct grade engine oil is essential for proper operation. If your vehicle is equipped with a manual transmission, make sure the parking brake is set fully before you turn the key.
  • Page 13 Driving 2. When the glow plug pre-heat indicator turns off, turn the key to 5 (START), then release the key as soon as the engine starts. The glow plugs will continue to be activated for two minutes after the glow plug pre-heat indicator has turned off.
  • Page 14 Driving Operation in snow Vehicle operation in heavy snowfall or in dry loose snow that may swirl around the front of the vehicle may feed excessive amounts of snow into the air intake system. This could plug the air cleaner with snow and cause the engine to stall and/or lose power.
  • Page 15 Driving Trailer towing tables - E-Series Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) E-350 Regular Van (9500 GVWR) 6.0L 3.55 7257 (16000) 4400 (9700) 6.0L 4.10 9072 (20000) 4536 (10000) E-350 Regular Van (Crew) (9500 GVWR) 6.0L 3.55 7257 (16000)
  • Page 16 Driving Trailer towing tables - Excursion & F-Super Duty Excursion Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) 6.0L 3.73 9072 (20000) 4988 (11000) 6.0L 3.73 9072 (20000) 4990 (11000) F-250 Engine Rear axle Maximum GCWR - Maximum ratio...
  • Page 17 Driving F-250 Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) SuperCab Pickup 4x4 with automatic transmission and fifth wheel 6.0L 9072 (20000) 5578 (12300) Crew Cab Pickup 4x2 with manual transmission and fifth wheel 6.0L 9072 (20000) 5850 (12900)
  • Page 18 Driving F-350 Regular Cab Dual Rear Wheel Pickup Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) Vehicles without fifth wheel 6.0L 9072 (20000) 6031 (13300) 4x2 with manual transmission and fifth wheel 6.0L 9072 (20000) 6031 (13300) 4x2 with automatic transmission and fifth wheel...
  • Page 19 Driving F-350 SuperCab Dual Rear Wheel Pickup Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) 4x2 with fifth wheel 6.0L 9072 (20000) 5895 (13000) 4x4 with fifth wheel 6.0L 9072 (20000) 5714 (12600) F-350 Crew Cab Single Rear Wheel Pickup Engine Rear axle...
  • Page 20 Driving F-350 Regular Chassis Cab Single Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) 6.0L 9072 (20000) 5942 (13100) 6.0L 9072 (20000) 5761 (12700) F-350 Regular Chassis Cab Dual Rear Wheel (Fifth Wheel Towing) Engine Rear axle...
  • Page 21 Driving F-350 SuperCab Chassis Cab Dual Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) 4x2 with manual transmission 6.0L 9072 (20000) 5623 (12400) 4x2 with automatic transmission 6.0L 9072 (20000) 5668 (12500) 4x4 with manual transmission...
  • Page 22 Driving F-350 Crew Cab Chassis Cab Dual Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) 4x2 with automatic transmission 6.0L 9072 (20000) 5579 (12300) 4x4 with manual transmission 6.0L 9072 (20000) 5306 (11700)
  • Page 23 Driving F-550 Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) Regular Chassis Cab 4x2 6.0L 11793 (26000) 8165 (18000) Regular Chassis Cab 4x4 with manual transmission 6.0L 11793 (26000) 7981 (17600) Regular Chassis Cab 4x4 with automatic transmission 6.0L 11793 (26000) 8029 (17700)

  • Page 24: Roadside Emergencies

    Roadside emergencies Roadside emergencies JUMP STARTING YOUR VEHICLE (E-SERIES ONLY) F-Super Duty and Excursion vehicles equipped with the 6.0L diesel engine can be jump started using the same procedure as a gasoline engine; refer to your Owner’s guide for the jump starting procedure.
  • Page 25 Roadside emergencies • Location of positive (+) jumper stud; remove the cap to access the jumper stud. 4. Check the assisting vehicle battery terminals and the positive (+) jumper stud and remove any excessive corrosion before you attach the battery cables. Ensure that accessible vent caps are tight and level. 5.
  • Page 26 Roadside emergencies 2. Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery. 3. Connect the negative (-) cable to the negative (-) terminal of the assisting battery.
  • Page 27 Roadside emergencies 4. Make the final connection of the negative (-) cable to an exposed metal part of the disabled vehicle’s frame or chassis, away from the batteries. Do not use fuel lines, brake lines, exhaust components or the battery trays as grounding points. Do not connect the end of the second cable to the negative (-) terminal of the battery to be jumped.
  • Page 28 Roadside emergencies Removing the jumper cables Remove the jumper cables in the reverse order that they were connected. 1. Remove the jumper cable from the ground metal surface. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery. 2.
  • Page 29 Roadside emergencies 3. Remove the jumper cable from the positive (+) terminal of the booster vehicle’s battery. 4. Remove the jumper cable from the positive (+) jumper stud of the disabled vehicle. Reinstall the cap onto the jumper stud. After the disabled vehicle has been started and the jumper cables removed, allow it to idle for several minutes so the engine computer can relearn its idle conditions.

  • Page 30: Cleaning

    Cleaning Cleaning ENGINE Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal. When washing: • Take care when using a power washer to clean the engine. The high-pressure fluid could penetrate the sealed parts and cause damage.
  • Page 31 Cleaning • E–Series...

  • Page 32: Maintenance And Specifications

    Maintenance and Specifications Maintenance and Specifications IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT E-Series 1. Windshield washer fluid reservoir 2. Automatic transmission dipstick 3. Engine oil filler cap 4. Secondary fuel filter assembly 5. Power steering fluid reservoir 6. Brake fluid reservoir 7.
  • Page 33 Maintenance and Specifications F-Super Duty/Excursion 1. Battery (dual batteries shown) 2. Air filter assembly 3. Power steering fluid reservoir 4. Clutch fluid reservoir (if equipped) 5. Brake fluid reservoir 6. Engine coolant reservoir 7. Engine oil dipstick 8. Engine-mounted fuel filter assembly 9.
  • Page 34 Information section of this supplement are required because they are considered essential to the life and performance of your vehicle. Use only recommended fuel, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft parts are designed and built for best performance in your vehicle. FUEL REQUIREMENTS The engine is designed to use low sulfur number 1–D or 2–D diesel fuel...
  • Page 35 Maintenance and Specifications Do not crank the engine for more than 30 seconds at a time as damage to the starter motor may result. If the engine fails to start in 30 seconds, turn the key to the OFF position and wait 30 seconds before trying again. Truck stops have pumps and nozzles designed for larger, heavy-duty trucks.
  • Page 36 IN FUEL light will come on when approximately 100 cc (0.2 pints) of water accumulates in the module. Replace the fuel filters with Ford Part No. FD–4604. This part number includes filters and seals for both the engine-mounted and frame-mounted filters.
  • Page 37 Maintenance and Specifications • F-Super Duty/Excursion • E-Series 3. Remove the drain plug, using a 6mm hex drive, by turning it counterclockwise. Allow the HFCM/FCM to drain for approximately 25 seconds or until clean fuel is observed. Install the drain plug by turning it clockwise until it is firmly seated.
  • Page 38 Maintenance and Specifications 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating surfaces. Removal - FCM filter (E-Series) 1. Remove the fuel filter cap by turning counterclockwise. 2. Remove and discard the old fuel filter element. 3.
  • Page 39 The engine will not run properly if the fuel filter is not installed in housing. 1. Install the new fuel filter and cap seal (from Ford Part No. FD–4604) into the fuel filter housing. 2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into...
  • Page 40 For normal or severe service, use Motorcraft oil or an equivalent oil conforming to Ford Specification WSS-M2C171–D or API Service categories CI-4, CI-4/SL or DHD-1. If CI-4 oil is not available, CH-4 is...
  • Page 41 Engine oils with improved fuel economy properties (energy conserving) are currently available. If you use an energy conserving oil, be sure it meets the recommended Ford Specification, API service categories and SAE viscosity grades listed in the Lubricant and Maintenance Materials Specifications chart.
  • Page 42 • Change engine oil and filter every 8,000 km (5,000 miles). • Use Motorcraft oil or an equivalent oil conforming to Ford Specification WSS-M2C171–D or API categories CI-4, CI–4/SL or DHD-1. If CI-4 oil is not available, CH-4 is acceptable.
  • Page 43 Maintenance and Specifications REPLACING THE AIR FILTER ELEMENT When replacing the air filter element, use the Motorcraft air filter element listed. Refer to the Motorcraft part numbers chart in this section. Note: Do not start your engine with the air cleaner removed and do not remove it while the engine is running.
  • Page 44 • Add Motorcraft Premium Gold Engine Coolant (yellow-colored), VC-7–A (U.S., except CA and OR), VC-7–B (CA and OR only), meeting Ford Specification WSS-M97B51–A1. Note: Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, may darken the color of Motorcraft Premium Gold Engine Coolant from yellow to golden tan.
  • Page 45 Maintenance and Specifications CXC-209 (Canada), meeting Ford specification WSS-M97B44–D with the factory-filled coolant. Mixing Motorcraft Speciality Orange Engine Coolant or any orange-colored extended life product with your factory filled coolant can result in degraded corrosion protection. • A large amount of water without engine coolant may be added, in case of emergency, to reach a vehicle service location.
  • Page 46 Recycled engine coolant Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles originally equipped with Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available.
  • Page 47 Maintenance and Specifications • Increased engine coolant concentrations above 60% will decrease the overheat protection characteristics of the engine coolant and may cause engine damage. • Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle will provide adequate freeze protection at the temperatures in which you drive in the winter months.
  • Page 48 Maintenance and Specifications NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS AND MAINTENANCE On January 1, 1978, Federal regulation became effective governing the noise emission on trucks over 4,536 kg (10,000 lbs.) GVWR (Gross Vehicle Weight Rating). The following statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Facts Booklet, are applicable to complete chassis cabs over 4,536 (10,000 lbs.) GVWR.
  • Page 49 Maintenance and Specifications If these checks do not help you correct the engine performance problem you are experiencing, consult an authorized dealer. FUELING Do not use starting fluid such as ether or gasoline in the diesel air intake system. Such fluids can cause immediate explosive damage to the engine and possible personal injury.
  • Page 50 Maintenance and Specifications • If all electrical connections are tight and you need assistance to start, refer to Jump starting in the Roadside Emergencies chapter of your Owner Guide (F-Super Duty and Excursion) or refer to the Jump starting section of this supplement (E-Series). If engine cranks but won’t start Prolonged starter cranking (in excess of 30 seconds) could cause damage to the starter motor.
  • Page 51 5.5L (5.8 quarts) Automatic transmission Refer to your Owner’s Guide Includes heater and 4.7L (5.0 quarts) in coolant recovery. Includes 1.0L (1 quart) in engine oil filter. Use Motorcraft MERCON ATF, Motorcraft part number XT-2–QDX, meeting Ford specification MERCON .
  • Page 52 Maintenance and Specifications BULB SPECIFICATIONS Number of bulbs Trade number Lamp description required Wait to Start Light Water-in-Fuel Light Engine Temp. Light LUBRICANT SPECIFICATIONS Ford Part Ford Part Ford Item Name Number Specification Motorcraft Motor Oil 15W40 XO-15W40-QSD, WSS-M2C171-D, Engine Oil...

  • Page 53: General Owner's Information

    2. If the inquiry or concern remains unresolved, contact the Sales Manager or Service Manager at the dealership. 3. If the inquiry or concern cannot be resolved at the dealership level, please contact the Ford Customer Assistance Center. In the US, contact: Ford Motor Company Customer Assistance Center 16800 Executive Plaza Drive, P.O.
  • Page 54 Allen Park, MI 48101 U.S.A. Telephone: (313) 594-4857 Fax: (313) 390-0804 E-mail: wdmocac@ford.com In the Middle East and North Africa, contact: Ford Middle East and North Africa Customer Assistance Center API World Tower 17 Floor Sheikh Zayed Road Dubai, United Arab Emirates...
  • Page 55 Your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Quality Care Center has factory trained technicians who can perform the required maintenance using genuine Ford parts. They are committed to...
  • Page 56 Quality Care - one stop for all your maintenance needs When you need maintenance for your Ford, Lincoln or Mercury vehicle, there’s only one name to remember: Quality Care, available at your Ford and Lincoln Mercury dealership. From scheduled maintenance to more complicated repair work, nobody knows your car or truck better.
  • Page 57 General Owner’s Information The right prices Our commitment to quality extends to pricing as well as service. Your Ford and Lincoln Mercury Dealership offers competitive prices on Genuine Ford and Motorcraft parts and services, making Quality Care a great value.
  • Page 58 Additional information available on the Web To learn more about the importance of routine and dealer-performed maintenance on your vehicle, please visit the Ford Customer Service website. You’ll also find important warranty information, customer assistance, technical expertise, frequently asked questions and much more.
  • Page 59 General Owner’s Information • Check wheels for end play and noise • Inspect and lubricate 4x4 u-joints (except F-450/F-550) • Inspect and lubricate steering idler arms, linkage, driveshaft(s) and front 4x4 front axle u-joint • Replace cabin air filter, if equipped 36,000 km (22,500 miles) •...
  • Page 60 General Owner’s Information • Replace engine- and frame-mounted fuel filters • Inspect and lubricate steering linkage, ball joints, idler arms, suspension and, if equipped, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields •...
  • Page 61 General Owner’s Information 108,000 km (67,500 miles) • Change engine oil and replace oil filter • Inspect engine air filter minder, replace filter as required 121,000 km (75,000 miles) • Change engine oil and replace oil filter • Inspect tires for wear and measure tread depth •...
  • Page 62 General Owner’s Information • Change automatic transmission fluid and external filter element • Check wheels for end play and noise • Inspect and lubricate 4x4 u-joints (except F-450/F-550) • Replace cabin air filter, if equipped 157,000 km (97,500 miles) • Change engine oil and replace oil filter •...
  • Page 63 General Owner’s Information • Inspect engine air filter minder, replace filter as required • Replace engine- and frame-mounted fuel filters • Inspect and lubricate steering linkage, ball joints, idler arms, suspension and, if equipped, driveshaft and u-joints • Inspect engine cooling system and hoses •...
  • Page 64 General Owner’s Information 229,000 km (142,500 miles) • Change engine oil and replace oil filter • Check air filter minder, replace filter as required 241,000 km (150,000 miles) • Change engine oil and replace oil filter • Inspect tires for wear and measure tread depth •...
  • Page 65 Normal vehicle axle maintenance Rear axles and power take off (PTO) units containing synthetic lubricant and light duty trucks equipped with Ford-design axles are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or the axle assembly has been submerged in water.
  • Page 66 General Owner’s Information Every 5,000 miles: Inspect brake system. Inspect and lubricate 4x2 ball joints and steering idler arms 30,000 miles and 90,000 miles: Lubricate 4x2 wheel bearings. Replace wheel bearing grease seal. Every 60,000 miles: Change transfer case fluid As required: Replace cabin air filter, if equipped Operating in dusty conditions such as unpaved or dusty roads Every 5,000 miles or 6 months: Change engine oil and replace filter...
  • Page 67 MAINTENANCE AND SERVICE RECORD See an authorized dealer This section of the guide is designed to allow your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Auto Care service center or other qualified service technician to record that the recommended service was completed at the appropriate mileage intervals.
  • Page 68 General Owner’s Information General Owner’s Information YELLOW COOLANT CHANGE RECORD Dealer’s Stamp: Date: 3 Years Next Date Current Mileage: 50,000 Miles + 50,000 Next Mileage: Dealer’s Stamp: Date: 3 Years Next Date Current Mileage: 50,000 Miles + 50,000 Next Mileage: Dealer’s Stamp: Date: 3 Years...