Table Of Contents - Ford 6.0L POWER STROKE Service Procedures And General Diagnostics

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
Front Of Engine10
Left 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
Single Mass Flywheel16
Normal Heat Treatment Discoloration16
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
Cooling System Flow: Egr Cooler20
Water Pump & Front Cover20
Injector Sleeve20
Glow Plug Sleeve21
Coolant Recovery Bottle21
Lubrication System Features22
System Flow22
L U B R I C A T I O N S Y S T E22
Lubrication System Oil Flow23
Lube Pressure Oil System Schematic23
Oil Pan / Bed Plate23
Oil Pick-Up Tube24
Pick-Up Tube / Oil Aeration24
Oil Pressure Regulator24
Gerotor Oil Pump24
Front Cover25
Oil Cooler25
Oil Cooler Housing & Filter Base25
Oil Filter Base & Valves26
Oil Filter26
Oil Reservoir & Screen26
Oil Temperature Sensor26
Oil Pressure Switch26
Oil Flow At Oil Reservoir27
Turbocharger Oil Supply & Vgt Control27
Turbocharger Oil Drain Tube27
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
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 Closed37
Vgt Turbine Vanes Partially Closed37
Vgt Turbine Vanes Open37
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
Three Stages Of Injection46
Stages Of Injection46
Fill Cycle46
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
Actuators65
Ipr (Injection Pressure Regulator)65
Egr (Exhaust Gas Recirculation) Valve65
Vgtcv (Variable Geometry Turbocharger Control Valve)66
Other Electrical Components66
Ficm (Fuel Injection Control Module)66
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
Egr Cooler: Removal & Installation75
Turbocharger Oil Supply: Removal75
Crankcase Ventilation: Removal / Oil Carryover75
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
Air In Fuel80
High Boost/High Ep At Wot No Load80
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
Crankcase Pressure Test83
Injector Buzz/No Buzz83
Appendix84
Special Torque Chart85
T O R Q U E C H A R T85
Cylinder Head Bolts87
Flywheel Bolts87
High Pressure Oil Rail Bolts88
Intake Manifold Bolts88
Main Bearing Bolts88
Hard Start/No Start Diagnostics89
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
Performance Diagnostics90
P E R F O R M A N C E D I A G N O S T I C90
Wiring Diagram91
Diagnostic Codes95
D I A G N O S T I C C O D E95
G L O S S A R98
Index101
N O T E104