6.4L Overview
Contents
1. 2008 F SERIES SUPER DUTY Engine Description Systems Overview Component Location Technician Tips FORWARD This publication is intended to provide technicians and service personnel with an overview of technical advancements in the 6 4L POWER STROKE DIESEL Engine The information contained in this publication will supplement information contained in available service literature IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe reliable operation of all motor vehicles as well as the personal safety of the individual performing the work This manual provides general directions for accomplishing service repair work with tested effective techniques Following the directions will assure reliability There are numerous variations in the procedures techniques tools parts for servicing vehicles and the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly anyone who departs from the instructions provided in this manual must first establish that they do not compromise their personal safety or the vehicle integrity by their choice of methods tools or parts The following list contains some general WARNINGS that you should follow when you work on a vehicle Always wear safety glasses for eye protection Always perform work in a well ventilated area Use safety stan2. Front of Engine 1 ECT Sensor 2 Fuel Return Line 3 EGR Cooler Vertical 4 EGR Throttle Left Front of Engine 1 EGR Cooler Horizontal 2 EGR Cooler Vertical 3 Coolant Supply for Horizontal Cooler 4 Coolant Supply for Vertical Cooler 5 Turbocharger Outlet COMPONENT LOCATIONS l 3 Left of Engine 1 Thermostat Housing Outlet 2 CMP Sensor 3 Oil Level Gauge 4 Fuel Supply Line 6 EP Sensor 7 Glow Plug Harness 5 Fuel Return Line 8 Heater Return Line 9 Degas Bottle Return Line Left Rear of Engine 1 EP Sensor 2 Turbocharger Crossover Tube COMPONENT LOCATIONS 11 Rear of Engine 1 Exhaust Expansion Joints 2 Catalyst 3 Lifting Eye 4 Serial Number 5 Turbocharger Outlet to Exhaust System Right Rear of Engine 1 Block Heater 2 EGRT Inlet Sensor COMPONENT LOCATIONS Right Side of Engine 1 CKP Sensor 2 Glow Plug Control Module Ng 4 Oil Seperator Drain Tube v 3 Crankcase Ventilation Oil Separator Wi 5 Heater Supply M 4 x o l be per ad M Right Front of Engine 1 Injector Electrical Connector 2 Throttle Body 12 COMPONENT LOCATIONS 13 Top of Engine 1 High Pressure Turbocharger 2 Low Pressure Turbocharger 3 Turbocharger Oil Supply Line 4 EGR Valve Coolant Supply Port 5 EGR Valve Coolant Return Port Deaeration
3. SENS ONS RTT TT TET 52 Control Devices sss 68 Glow Plug Control Module GPCM 0 ccc cece eee eee ee eee eens 70 UNIQUE SERVICE PROCEDURES 73 APPEND X 0220002000000 002 31 Torque Charts 22 ccc cece ccc cece eee eee e eens mnn 82 Wiring Diagram 00 c cece eee cece IRR 38 Diagnostic Trouble Codes DTC s 222222020000220 90 This page intentionally left blank Power Stroke Diesel Direct injection Turbocharged Diesel Engine 6 4L POWER STROKE DIESEL OVERVIEW 6 4L Power Stroke Diesel Overview 6 4L Power Stroke Diesel e This publication is not intended to replace the Service Manual Direct Injected Turbocharged but to introduce the 6 4L Power Stroke Diesel Engine Diesel Engine Overview e Engine Features e Horsepower amp Torque e Engine Specifications e Physical ID e Labeling EEL Engine Features Engine Features e The 6 4L Power Stroke Diesel has been designed to meet the tougher emissions standards set by the government _ e High Pressure Common Rail Fuel System e The 6 4L Power Stroke Diesel has been designed to meet the customers expectations of high e Series Sequential Turbocharger horsepower and torque over a wide RPM range e Meeting the more stringent customer and regulated e 4 Valves per Cylinder demands are accomplished in
4. LES FOR A COMPLETE VEHICLE 8 501 TO 14 000 POUNDS ENGINE CORPORATION GVWR AND A MAXIMUM FRONTAL AREA OF 45 SQUARE FEET THIS ENGINE MEETS OBDII REQUIREMENTS AND U S EPA REGULATIONS AND OBD INTERNATIONAL REGULATIONS CANADIAN AND AUSTRALIAN ADR 30 REGULATIONS FOR THE 2006 MODEL YEAR AND IS CERTIFIED TO OPERATE ON DIESEL FUEL e s affixed to the right hand valve cover 187433262 THIS ENGINE IS INTRODUCED EARLY PURSUANT TO 86 007 11 g 2 AND CERTIFIED TO THE PM STANDARD OF 0 01 g BHP HR e F250 350 labels are red MODEL e F450 550 labels are blue 7 2006 CURB IDLE FUEL RATE ADVERTISED POWER qne AND INJECTION TIMING ARE NON ADJUSTABLE EMISSION CONTROL EMISSION CONTROL SYSTEM ECM TC DI CAC EGR OC PTOX INFORMATION DISPLACEMENT 6 4L ENGINE MANUFACTURED BY IMPORTANT ENGINE INFORMATION INTERNATIONAL TRUCK THIS ENGINE HAS A PRIMARY INTENDED SERVICE APPLICATION AS A AND LIGHT HEAVY DUTY DIESEL ENGINE AND CONFORMS TO U S EPA ENGINE CORPORATION CALIFORNIA CANADIAN AND AUTRALIAN ADR 30 REGULATIONS FOR INTERNATIONAL THE 2006 MODEL YEAR AND IS CERTIFIED TO OPERATE ON DIESEL FUEL THIS ENGINE IS INTRODUCED EARLY PURSUANT TO 86 007 11 g 2 AND KI 1874333C2 CERTIFIED TO THE PM STANDARD OF 0 01 g BHP HR 8 e Shows the engine displacement o SE zz do o o as uu HC NOx PART 1 3 1874333C2 U S FED FAMILY EMISSION LIMITS COMPONENT LOCATIONS
5. Port 6 EGRT Outlet Sensor 7 MAP Sensor 8 IAT 2 Sensor Top of Engine 1 Oil Filter 2 Engine Mounted Fuel Filter 3 Catalyst 4 Fuel Cooler 5 Fuel Cooler Coolant Tank 7 Fuel Return Cold outlet from cooler 8 LH High Pressure Fuel Line 9 EGR Valve 6 Fuel Return Hot inlet to cooler 10 ECM Connection 6 4L POWER STROKE DIESEL OVERVIEW Nd 1 High Pressure Common Rail Fuel System P sc e The 6 4L Power Stroke Diesel engine uses a high pressure fuel injection pump to deliver fuel to each piezo electric fuel injector via a high pressure common fuel rail one rail per bank 18 Cylinder Head amp Head Bolts e The 6 4L Power Stroke Diesel uses a four 4 valve per cylinder head design to optimize airflow and efficiency e The 6 4L Power Stroke Diesel engine uses larger head bolts than the 6 0L Power Stroke Diesel engine M16 vs M14 e The 6 4L head bolts are also slightly shorter than the 6 0L head bolts The 6 4L head bolts do not retain the rocker carrier like the 6 0L head bolts do 19 Fulcrum Plate amp Rocker Arms e The fulcrum plate which holds the rocker arms is bolted to the rocker pedestal e The two 2 bolts that secure the fulcrum plate pass through the fulcrum plate and the rocker pedestal and are then secured into the cylinder head 20 6 4L POWER STROKE DIESEL OVERVIEW C Rocken Rocker Pedestal hd e The
6. TT T ee ae 6 Horsepower amp TOrQue 0 ccc ccc cece cece eee eee e IHR 6 Specifications uaa aan ae ocean ne saree icone evden eain EE sate re 7 Identification NOTET TOT 8 COMPONENT LOGATIONS 9 a ee ee ee dd 14 COOLING SYSTEM 222 222000220000000 16 Internal Coolant Flow sessssnnnnn Rem 16 External Coolant FloW 0 cece cece cece cece eee eee ee II 17 Coolant Pump 200222202 000 NA cece cece cece IH HHHHens rne 19 LUBRICATION SYSTEM 21 Base Engine FIOW 0 ccc cece cece NB cece este Hem 21 System BOW aga ersetzende 22 FUEL SUPPLY SYSTEM 28 System Flow 222022 222 Hh nnns 29 AIR MANAGEMENT SYSTEN 33 System PONG pan KONG AN esas EE haud brad Eri SC prradd IPM FPE I 34 Series Sequential Turbocharger 0 ccc ccc cece cece eee e seen eee e es 36 it mc 39 FUEL MANAGEMENT SYSTEM 41 System FIOI AMA ara AA AA 42 High Pressure Fuel Injection Pump Flow esee 43 Piezo Fuel InIeblOI S ce ect sein ces BA obtu d ha OR DD SERA E PESE 45 Stages of Injection ssssssssesssnnnn HR 47 ELECTRICAL COMPONENTS 51
7. ds whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Never perform any service to the engine with the air cleaner removed and the engine running unless a turbocharger compressor inlet shield is installed Set the parking brake when working on the vehicle If you have an automatic transmission set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE engine OFF or NEUTRAL engine ON unless instructed otherwise for a specific service operation Operate the engine only in a well ventilated area to avoid the danger of carbon monoxide Keep yourself and your clothing away from moving parts when the engine is running especially the fan belts and the turbocharger compressor To prevent serious burns avoid contact with hot metal parts such as the radiator turbocharger pipes exhaust manifold tail pipe catalytic converter and muffler Do not smoke while working on the vehicle To avoid injury always remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle Tie long hair securely behind the head Keep hands and other objects clear of the radiator fan blades This page intentionally left blank 6 4L POWER STROKE DIESEL TABLE OF CONTENTS OVERVIEW 6 PO ULOT ve czas ccna rout ea
8. nt on the left side 2 4 6 8 6 4L POWER STROKE DIESEL OVERVIEW Engine Serial Number Si FRANKE F NE e The engine serial number is located on the left rear corner of the crank case on a half moon machined surface A white sticker is placed over this number during production this sticker was removed for illustration purposes 6 4 is the engine family identifier HU2Y is a manufacturing designator Ex HU2Y or HU2U Y designates Huntsville AL and U designates Indianapolis IN e 0385535 is a sequential build number 5 Serial Number Label e Located on the top of the vertical EGR cooler e States the engine serial number example at right 0385535 h S an BR a a LULU TERNATIONAL ui DI TURBO DIESEL HUNTSVILLE ENGINE PLANT EN100 051006 0385535 MOLLIT e States the engine family example at right 6 4L DI turbo diesel ED on ne Es SY 2006 HE H e he horsepower ratina for the enain CURB IDLE FUEL RATE ADVERTISED POWER States the nes i at r y i hi m seio ep Pap AND INJECTION TIMING ARE NON ADJUSTABLE Z programmed in the Engine Control Module ECM E EMISSION CONTROL SYSTEM ECM TC DI CAC EGR OC PTOX ol I e Depicts where the engine meets or ENGINE MANUFACTURED BY IMPORTANT ENGINE INFORMATION NG up THIS ENGINE CONFORMS TO exceeds emission standards INTERNATIONAL TRUCK CALIFORNIA REGULATIONS APPLICABLE TO 2006 MODEL YEAR ULEV AND MEDIUM DUTY VEHIC
9. part by High Pressure i Common Rail Fuel System Series Sequential Turbocharger e Rear Gear Train System 4 valves per cylinder and a dual timing system e Dual Timing System 2 25S Horsepower amp Torque e The 6 4L Power Stroke Diesel creates 350 horsepower at 3000rpm and 650 Ib ft of torque at 2000rpm engine speed rpm Torque lb ft Horsepower bhp 6 4L POWER STROKE DIESEL OVERVIEW 6 4L Power Stroke Diesel Specifications Engine Type Diesel 4 Cycle Configuration 4 OHV 1 Cam in Crankcase V8 Displacement 390 cu in 6 4L BORG ULL On 3 87 X 4 134 98 2 X 105 mm Compression Ratio Aspiration Series Sequential Turbo with CAC Rated Power RPM 350 3000 RPM Peak Torque RPM 650 2000 RPM Engine Rotation Facing Flywheel Counter Clockwise Combustion System High Pressure Common Rail Direct Injection Total Engine Weight auto with oil 1130 Ib 498 95 kg Coolant Flow to radiator 125 gal min 473 L min 3000 RPM Air Flow RPM compressor inlet 744 CFM 21 1 m3 min 3000 RPM Exhaust Flow RPM engine outlet 1962 CFM 55 6 m3 min 3000 RPM Oil Flow RPM 13 gal min 59 L min 3000 RPM Cooling System Capacity engine only 25 3 qts 24 L Lube System Capacity including filter 15 qts 14 2 L Firing Order 1 2 7 3 4 5 6 8 L Front R Specifications e The cylinders of the 6 4L Power Stroke Diesel are numbered from the front on the right side 1 3 5 7 and from the fro
10. rocker pedestal is secured independent of N the cylinder head bolts which no longer need to be removed to service the rocker arms High Pressure Fuel Injection Pump amp Rear Geartrain e The geartrain for the crankshaft camshaft and the high pressure fuel injection pump are located in the rear of the engine under the rear cover Lich Pressure ual Infection Pump Gear e This allows for the high pressure fuel pump to be mounted inside the engine and also reduces noise e The high pressure fuel injection pump turns at a ratio of 1 1 with crankshaft speed Camshant Gear NOTE The helical cut gears used on the 6 4L differ from those used on the 6 0L Cetak Gear 22 6 4L vs 6 0L Flexplate e The flexplate for the 6 4L automatic equipped engine uses an 8 bolt torque converter bolt pattern e The flexplate for the 6 0L automatic equipped engine uses a 6 bolt torque converter bolt pattern NOTE Yellow circle added for bolt circle reference 15
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