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6.0L Technician Reference Manual

1. Engine Mounted Components SENSORS Regulator Sense Bt cki ee a EGT MAT EP EFC Module CRANK POSITION a ON A j POSITION l Sense Sensor im AAA Es TPWRGND Il AIC Clutch Alternator zz m Alternator E YN c A 1 An Bf cl A N Power Y UN O NY Tt Ty Tr IE LT ee eee AAA IA A A i eee BE A E Y EEE AS EEE A AE AA O E E E DEN EEE BREEN N Ei A E a E E HO O DE O A fp E pt A Aa A ee N SS FCHEN LI A IN El AAA i S y EN El AN WA VEIA YE EEE DEE DEN EI A A ll ly IN IE E E a VE VER EEE BEE IS E A A E E E TI A VE NE TE EEE I f 1 i L H EGR IPR VGT Actuator Actuator Actuator Orientation Looking into terminals on connector PURPLE V inj 48 VOLTS Lt BLUE V ref 5 VOLTS GREEN SIGNAL CIRCUIT Dk Blue Data Communication Link BLACK GROUND CIRCUIT RED 12 VOLTS V Batt AGold Plated Pins i Glow Plug ControlModule 90 Intake Throttle Position Actuator Cylinder 2 Cylinder 1 Cylinder 4 Cylinder 3 FUEL INJECTORS Cylinder 5 Cylinder 7
2. FICM CAN Programming Connector AUN Injector Pinout Open Coil Power Open Coil Ground Close Coil Power Close Coil Ground q 1111 7 X1 Pin 20 X2 Pin 4 X3 Pinto H FETT BEE A Siemens FICM Module ATA WIRING DIAGRAM SINGLE ALT 12 Way On Off Engine Connector A C Clutch Type 4 7 A C Clutch aa wa Ground AHC WE ie 3 FICM Power C Rela PCM Power V Power r FFH Relay Al y Relay FP Relay Ignition Switch FICM Ground a Type 4 Module B VPWR KEYPW VPWR Fuel Pump i E a Ground 0 B 0 B D B I B i je 15A gt FICM Logic Pwr mp 50 Amp B MPR E E M 8 Key Power KEYPWR Type 4 Inertia EOP Switch ern uy Ground Switch 8 Way On Off DFCM Mod I Sense 6 Engine Connector a IEA a BE _ Type 2 3 yp C z Ground Vehicle Mounted Components GEN2M 5 BAP GEN1M ra H INTRUMENT CLUSTER O Visteon MAF MAP AHC Diagnostics Connector pS O KEYPWR 5 NX J1 C1 Pocket Sa GEN1C E M O 1 PCM122 Chassis Ri GEN2C 4 Connector 46 1000 DOs a A O TPWRGND 55 Way D 2 ODOMonts FSS a VPWR VBPWR ae 2 KAPWR B M g A TOD LEN ope 1 FOV 2 40 PWRGND AN APCM EPATS VGTCH Esa 3 11 23 Module Module w pa m 3
3. AAA Oe 18 COOLING SYSTEM iele ktk INJECTOR SLEEVE 32 Cooling System Flow EGR Cooler Coolant flows out of the filter base and into the EGR cooler through a tube that directs the coolant to the back of the EGR cooler Coolant flows through the EGR cooler and removes heat from the exhaust gasses before the exhaust arrives at the EGR valve Coolant exits the front of the EGR cooler and enters the coolant passage of the intake manifold The intake manifold directs the coolant back into the front cover O M Water Pump amp Front Cover The water pump hub and impeller is mounted into the front cover which is the housing for the water pump The water pump impeller pulls coolant from the center of the housing and pushes it outward The water pump has a built in reservoir to catch small amounts coolant that during normal operation of the engine may seep past the seal Note The water pump impeller may be damaged if dropped or hit by a hard object Injector Sleeve The 6 0L Power Stroke uses stainless steel injector sleeves to seal coolant from the injector and to transfer heat from the injector to the coolant The injector sleeve is replaceable See unique service procedures or service manual for more details 19 COOLING SYSTEM Glow Plug Sleeve e Glow plug sleeves are used to keep coolant from coming in direct contact with the glow plugs and to seal coolant from the combu
4. 96 Ibf in A 36 Ibf ft High pressure discharge tube mounting bolts 71 Ibflin High pressure cada nn 33 Ibf ft High pressure oil rail check valve o 0oooooocoocoronnnnann 25 Ibf ft High pressure oil rail plug M14 zusunnennnnennnnnn nenn 33 Ibf ft oo BETET 96 Ibf in High pressure oil rail bolt see figure C c eee eee 96 Ibf in High pressure pump cover bolts ccc cece cece eee eens 96 Ibf in High pressure pump cover plug c cece cece cece eee eee eee eens 26 Ibf ft High pressure pump drive gear bolt 0 0 95 Ibf ft High pressure pump mounting bolts 0o oo oo 18 Ibf ft Injection control pressure ICP SENSOT ccce eee eee ees 106 Ibf in Injection pressure regulator IPR cece cece eens 37 Ibf ft Intake air temperature 2 IAT2 sensor cece cece eee eens 13 Ibf ft Intake manifold see figure D c cece cece e nn nennen nn nenn 96 Ibf in oo 30 Ibf ft Lower crankcase main bolts see figure E o ooo oo figure A SS LULU 84 METRIC 5 Nm 13 Nm 11 Nm 31 Nm 45 Nm 68 Nm 41 Nm 7 Nm 20 Nm 11 Nm figure 10 Nm 6 Nm 13 Nm 31 Nm 13 Nm 12 Nm 12 Nm 27 Nm 38 Nm 12 Nm 12 Nm 30 Nm 27 Nm 27 Nm 94 Nm 24 Nm 38 Nm 43 Nm 26 Nm 33 Nm 27 Nm 19 Nm 8 Nm 11 Nm 11 Nm 49 Nm 8 Nm 45 Nm 34 Nm 45 Nm 11 Nm 11 Nm 11 Nm 35 Nm A 129 N
5. ELECTRICAL COMPONENTS Camshaft Position Sensor ES FICM Fuel Injection Control Module PCM Powertrain Control Module JUL Fuel Quantity Timing and Control CMP Malfunction Indicator Lamp CMP Camshaft Position e The camshaft position signal source is a magnetic pickup sensor mounted on the left front side of the engine block e The sensor reacts to a peg pressed into the camshaft at the front of the engine e The peg will pass the sensor once per camshaft revolution the sensor will produce a single pulse correspondingly e Camshaft speed is derived from the frequency of the CMP sensor signal CAMSHAFT TIMING PIN 107 PCM to the FICM so that the FICM can perform fueling calculations Diagnostic information on the CMP input signal is obtained by performing accuracy checks on signal levels frequency and or duty e The PCM conditions the signal and cycle with software strategies sends it out as TACH signal for body builder use The ECM needs both the CKP and CMP signal to calculate engine speed and position The CMP creates a signal that the PCM uses to indicate a particular bank The CMP contains a permanent magnet which creates a magnetic field when the magnetic field is broken by the peg on the camshaft a signal is created A conditioned CMPO Camshaft Position Output is sent from the 93 ELECTRICAL COMPONENTS Powertrain Control Module
6. cc cece cece eee eee eee eee en nn nennen 17 Ibf ft 23 Nm Turbo exhaust adapter v band clamp cccc cece ee ee eee 80 Ibf in 9 Nm Turbo oil Supply boltS cece eee nn nn nn nn nenn nenn 18 Ibf ft 24 Nm Turbo oil supply snap to connect fitting 08 8 13 Ibf ft 11 18 Nm Turbo to mounting bracket bolts see note 2 28 Ibf ft 38 Nm Turbo bracket to crankcase mounting bolts 23 Ibf ft 31 Nm Valve cover DOItS u ussuunnnunnnununnnunnnunnnunnn nenn nn nn nn nennen 71 Ibflin 8 Nm Vibration damper see note 5 initial ooooooo 50 Ibf ft 68 Nm Final o ooonnocooccoooo nne A additional 90 degrees rotation STANDARD TORQUE CHART Special Torque Chart Notes Hex Flange Head e 1 Tighten 2 M6 studs in front EGR cooler flange Thread Torque Torque Wrench first then install M8 EGR cooler support bolt Diameter Ibf ft Nm Size mm M6 x 1 8 11 8 e 2 Apply High Temperature Nickel Anti Seize ee A oe re i x Lubricant F6AZ 9L494 AA to threads of bolts M12x1 75 61 83 15 prior to aa e oe e 3 Lightly coat o ring with engine oil before Hex Mead installing M6 x 1 6 8 10 M8x1 25 15 20 13 e 4 Apply Threadlock 262 to bolt threads prior to M10 x 1 5 30 40 16 assembly M12 x 1 75 51 69 18 M16 x 2 128 173 24 e 5 Tighten bolts across center of crankshaft Always use new bolts in vibration damper Pipe Thread 1 8 NPT 7 10 2 1 4 NPT 10 13 6 3 8
7. monitoring MAF voltage is greaterh than 4 95 volts A 7 pressure expected for normal operations when BP is less than 0 04 volts Default 101 kpa 14 6 PSI P0108 C Manifold Absolute Pressure BARO Sensor High Input Checks BP for a signal greater than a specified barometric Circuit is shorted to power pressure expected for normal operations when BP is greater than 4 9 volts Default 101 kpa 14 6 PSI P0112 C Intake Air Temperature Circuit Low Input Checks sensor output for a value higher than a maximum Short to ground probable temperature when IAT voltage is less than 0 15 volts Default 77 F 25 C P0113 C Intake Air Temperature Circuit High Input Checks sensor output for a value lower than a minimum Open circuit short to power probable temperature when IAT voltage is greater than 4 9 volts Default 77 F 25 C temperature expected for normal operation when ECT P0117 C Engine Coolant Temperature Circuit Low Input Checks ECT for a temperature higher than a specified oil Short to ground on the circurt voltage is greater than 0 15 volts Default 1800F 820C no P0118 C Engine Coolant Temperature High Input Checks ECT for a temperature lower than a specified oil Open in circuit short to power T temperature expected for normal operation when ECT voltage is greater than 4 78 volts Default 1800F 820C no fast idle P0148 C FuelingError____________________ Engine RPM has exceeded requested RPM Alternative
8. P2291 ey Injector Control Pressure Too Low Engine Cranking No start ICP is less than 725psi 5mpa See diagnostic manual ICP system P2552 Ic O R FICMM Circuit Throttle Fuel Inhibit Circuit_______ No signal from the FICM Monitor circuit 22 Circuit open short FICM PCM P2614 C_ O R Camshaft Position Output Circuit 2 2 CMPO signal intermittent Poor connection electrical noise In CMPO from PCM P2617 IC O R Crankshaft Position Output Circuit Ss CKPO signalintermittent___________ Poor connection electrical noise In CKPO from PCM P2623 c O R Injector Control Pressure Regulator Circuit IPR circuit failure JOpen grounded circuit stuck IPR loose connection 96 GLOSSARY Actuator A device which delivers motion in response to an electrical signal Analog A continuously variable voltage APS Accelerator Position Sensor A potentiometer style sensor that indicates the operator s pedal position AWA Feature A feature built into the high pressure oil rails used to dampen noises that can be caused by the hydraulic system BARO Barometric Pressure Sensor An analog device which indicates atmospheric pressure which allows the PCM to compensate for altitude A BARO sensor has three connections signal return gnd BARO signal and Vref CAC Charge Air Cooling A process of cooling the air coming out of the turbocharger before it enters the engine Canister Style Oil
9. y Internal to PCM VGT Actuator Circuit check Diagnostic circuit associated with 1 Amp driver checks for open circuit Range Performance short to ground and short to power pen Intake Air Temperature Sensor 2 Circuit IAT 2 Biased Sensor System Fault PCM Range Performance P0097 C O R Intake Air Temperature Sensor 2 Circuit Low Input EGR disabled less than 0 15v MAT signal circuit shorted to ground or defective sensor P0098 C O R Intake Air Temperature Sensor 2 Circuit High Input EGR disabled greater than 4 8v MAT signal circuit open short to power or defective sensor P0101 oii Mass or Volume Air Flow Circuit Range Performance Indicates an MAF range performance problem was detected Damaged MAF sensor plugged or restricted sensor supply tube MAF during normal driving conditions when MAF is enabled 4 0 Volts when RPM is less than 1500 4 9 volts when RPM is greater than 1500 rpm P0102 C Mass or Volume Air Flow Circuit Low Input Indicates MAF sensor circuit low input was detected during Open MAF sensor circuit biased sensor PCM short to SIGN RTN or KOEO Self Test or during continuous diagnostic monitoring PVWWR GND on MAF sensor circuit open in VREF circuit MAF voltage less than 0 35 volts P0103 C Mass or Volume Air Flow Circuit High Input Indicates MAF sensor circuit high input detected during Biased sensor PCM MAF circuit shorted to VREF KOEO On Demand Self Test or during continuous diagnostic
10. If self test codes are retrieved go to appropriate PPT test seconds 10 Scan Tool Data List Monitoring Wait to Start Lamp on time is independent from g p on time e Scan tool may reset below 9 5 volts Glow Plug Resistance e Inspect exhaust system e Select the parameters indicated from the scan tool e Disconnect the 4 pin connector at front of valve cover parameter list and monitor while cranking engine e Measure each Glow Plug resistance to Bat ground Method Parameter_ Spec Measurement e Measure engine harness resistance to GPCM Visual VPWR Glow Plug Harness to Sufficient Clean Fuel FICMLPWR svoltmin to Ground GPCM connector e Check if the WATER IN FUEL lamp has been FICMVPWR 1 to 2 ohms 0 to 1 ohms illuminated SS DE DER After verifying that there is fuel in the tank drain a minimum sample from fuel control module ICP 3 5 mPa min e Cetane rating between 40 50 is recommended for Gere optimum start ICPvolts 80Vmin Method ruerew soows 2ms Visual FICMSYNC_ Yes No A V PWR If low voltage condition is present check battery Electric Fuel Pump Pressure charging system or power gnd circuits to the PCM e Verify that the fuel pump has voltage and gnd At key on B FICMLPWR No low voltage indicated could be caused e Check if air filter minder indicator has been illuminated e Measure fuel pressure at engine fuel filter hou
11. SPRINGS 22 A F gt i DISSWEBREDERER 77a Dual Mass Flywheel The 6 0L Power Stroke uses two different flywheels for the manual transmission A dual mass flywheel is used on the F 250 350 Superduty truck The dual mass flywheel can be identified by springs located around the flywheel on the engine side It can also be identified by an extra ring of bolts on the transmission side of the flywheel that holds the two masses together From the side it can be identified by the separation between the clutch surface and the starter ring N Single Mass Flywheel A single mass flywheel is used on the F 450 550 Superduty trucks The single mass flywheel can be identified by the absence of the above mentioned parts and that it is machined from one solid part AAN Normal Heat Treatment Discoloration The bearing surfaces on the crankshaft are induction hardened During the hardening process the surrounding areas of the crankshaft discolor This condition is normal 15 16 This page intentionally left blank COOLING SYSTEM Cooling System Features Cooling System Features e The modular water pump can be serviced without disconnecting radiator hoses e Both the glow plug sleeves and the injector e Modular Water Pump sleeves are stainless steel e Stainless Steel Injector Sleeves e Stainless Steel Glow Plug Sleeves Cooling System Flow COOLING SYSTEM Cooling System Flow Fron
12. e Another label on the FICM is the part number and the FICM calibration label Emissions Label e States the horsepower rating for the engine programmed in the powertrain control module PCM e Depicts where the engine meets or exceeds emission standards 4 6 0 DIT ENGINE FAMILY INVXOG OAEA e Shows the engine displacement EMISSION CONTROL INFORMATION e Is affixed to the right hand valve cover DE DEPOLLUTION DE DEPOLLUTION ENGINE MANUFACTURED BY MOTEUR FABRIQUE PAR INTERNATIONAL TRUCK AND ENGINE CORPORATION INTERNATIONAL 184305062 behind the glow plug control module FAMILLE DE MOTEUR 6 0 DIT DES x 43 1 te E un MINI ve 3 ge A aT NTERNA 15 E 41 AC E T EN 9193 st TURBO DI aD al WW 1 2 Au uaa Inu dins POERA EA 2 qe gt xT Wo Y coment lastra d rapier 11 falet removal e M e362 u De x ET ur pres Se Je Pon e D gt ARTES an A F P PS SY Y ww CURB DER DE Si ADVERTISED POWER AND INJECTEON TIMING ARE LE UST LE REGIME DE AALENT LE DEBIT DE CARBURANT A LA PUISSANCE NOMINALE ET LE CALAGE DE LIHJEZTIGH SONT KOH REGLABLES EMISSION CONTROL SYSTEM SYST DE DEPOLLUTION ECM TC DI CAC EGR oc DISPLACEMENT CYLINDAEE 6 0L THES EMGIME HAS A PRIMARY INTENDED SERVICE APPLICATION AS 4 LIGHT HEAVY DUTY DIESEL Do an an Coo TOUS go CANADIAN AND
13. e Fuel Injection Control Module FICM e Powertrain Control Module PCM e Glow Plug System X1 CONNECTOR X2 CONNECTOR X3 CONNECTOR Turbocharger Control Valve is a duty cycle controlled valve that directs oil flow to the piston that controls the vanes in the turbocharger The valve controls pressure to both the open and close side of the piston If the valve is disconnected the turbocharger vanes will remain in a open state Da Other Electrical Components Other electrical system components include the FICM PCM and the glow plug system O FICM Fuel Injection Control Module The FICM Fuel Injection Control Module receives Information from the PCM like volume of fuel desired RPM EOT ICP and others and uses those signals to calculate injector start of injection and duration After calculating injector fuel delivery time the IDM sends a 48 volt 20 amp pulse to the correct injector so that the correct amount of fuel will be delivered to the cylinder at the correct time 65 ELECTRICAL COMPONENTS PCM Powertrain Control Module e The Powertrain Control Module PCM PCM which is mounted behind the battery on the y drivers side inner fender panel uses sensor Bi inputs to control actuators and send fueling commands to the FICM e The PCM controls the fuel and air management systems on the 6 0L Power Stroke Glow Plug System Glow Plug System Malfunction Glow Pl
14. e Refill crankcase with correct volume of recommended oil _ Fuel Filter Replacement e Remove the fuel filter lid and lift the filter element out of the housing and discard in a m the appropriate location FUEL FILFERSSCEN e To avoid fuel spills use a suction gun or Zn ss Tun ea simular device to remove the remaining fuel iu from the fuel filter housing r e Install the new filter and tighten the fuel filter lid to the specified torque e Note Before starting the vehicle cycle the key to the on position and let the fuel pump run a full cycle 3 times to ensure the fuel filter housing is full of fuel before starting the vehicle Injector Removal e After removing the valve cover s disconnect the snap to connect fitting for the high pressure oil line leading to the high pressure oil rail using tool 303 755 e Remove the eight 8 high pressure oil rail bolts that mount the oil rail to the rocker arm carrier e Pull the oil rail straight up to remove it e Note Do not pry against the valve cover sealing surface to remove the rail e Note Oil will come out of the rail when the rail is removed O 69 UNIQUE SERVICE PROCEDURES Injector Removal cont e The injector connectors on the 6 0L Power Stroke are locked into the rocker arm carrier e To disconnect the external engine wiring harness from the injector push in on the spring loaded metal clip on the harness e To r
15. 100 RUN INN RA SPOOLVALVE AT C LOSE D JT 5 NS 1 INTENSIFIER PISTON AT REST a Dele ol we 2 ELD ITE gt 9 9 g LE No 2 LIZ SS a q lt QUE SN Sas PINTLE CLOSED a Oil Pressure NA High Pressure Oil EEE Atmosphereic Pressure Fuel Pressure BEE Fuel Supply Pressure BEE Less Than 3100 PSI WM Above 3100 PSI 101 End of Main Injection Step 1 e When the IDM Injector Drive Module determines that the correct injector on time has been reached meaning that the correct amount of fuel has been delivered it sends a pulse width controlled current to the close coil of the injector e The current energizes the close coil Magnetic force moves the spool valve to the closed position e High pressure oil is dead headed against the spool valve O End of Main Injection Step 2 e The pulse width controlled current is shut off after 800 usec micro seconds or millionth of a second but the spool remains in the closed position e The intensifier piston and plunger begin to return to their initial position e Oil above the intensifier piston flows past the spool valve through the exhaust ports e Fuel pressure decreases until the nozzle needle control spring forces the needle back onto its seat 47 48 This page intentionally left blank ELECTRICAL COMPONENTS e Sensors e Actuators e
16. Cylinder 1 Regulator Sense Bt EFC Module EOP RUN Start VBPWR Switch Speed l Sense Sensor FA TPWRGND AIC Clutch Alternator Alt t 8 6 5 ernator To Battery Power 00 Elec Fan Ctrl Cylinder 4 Cylinder 6 Cylinder 8 ay 4 4fi Cylinder 5 Cylinder 7 Cylinder 3 RCS NC RCS NO A B MPR FICM Logic Pwr FICM Main Pwr FICM CAN 2 rogramming TA Connector 3 ATA ALA TA 1 Open Coil Power 2 Open Coil Ground 3 Close Coil Power 4 Close Coil Ground A C Clutch A C Clutch AHC V Power FICMLogic Pwr MPR Key Power EOP Switch I Sense GEN2C GEN1C sta 53 Ein 3 LOS Bins 4 23 X3 Pins 24 25 X3 Pins 1 2 3 X3 Pins 22 26 X3 Pin 30 X3 Lin 31 TEEN X3 Pin 29 X3 Pin 28 a x2 Pins X2 Pin 23 X2 PiN 7 X2 Pin 24 xi Pin4 X17 Pin 24 Xi Pin7 X1 Pin 1 X1 Pin 6 X Pn2 x2 Pin2 Xa Pini17 X2 Pin6 xf Pin2 XPni X1 Pin 20 X2 Pin4 X2 Pn19 x2 En 20 _ X2 Pin 1 X2 Pin21 X2 Pin5 X1 Pin3 X1Eintz__ AS X1_Ein18__ X3 Pin5_ X3 Bin 10 Siemens FICM Module Perera AHC GEN1C GEN2C TPWRGND FSS VBPWR FC V VGTCH SIGRTN CKP EGRVC EGRVP EGRTPC1 EGRTPC2 GPE GPD FICMM CAN2H CAN2L CKPO CMPO NOTE For clarity of the print all three FICM connectors are shown together as one The pin numbers are color coded red for X2 blue for X1 and black for X3 WIRI
17. EP 27 2 ACCR VREF 36 Fe FPC SIGRTN gt 35 mer BUS NU ba IAT2 45 44 BUS 25 ECT 7 FEPS u 2 EOT 44 779 SCIL Y ICP ru Er ACPSW A CMP 37 SIGRTN 2 RB Fr VREF CMP CKP Sh PWRGND m 42 MAF a a MAFRTN CKP A a IAT1 IPR 2 337 BARO VGTC Ho a MAP EGRVC 23 77 PBPP come e we ey EGRTP aa a APP2 EGRTPC1 72 9 VREF2 EGRTPC2 5 1 GRTPC Fr SIGRTN2 xx GPE a A APP3 T TA RAR 25 GPD 17 aa APP1 O FICMM ETE ae ACCS SI JE CAN2H ar Sar TOWS Auto KEYPWR o op To AC System S CAN2L y pees CPP Man KEYPWR CPSW NC Starter Relay CKPO 26 36_ 2 VPWR CTRL Ignition Switch 19 28 BPS G START CMPO gt BPP NC 20 18 By J ype2 F B TRO_PN NO Ground THREE J1 C2 Pocket _ WFS TRACK PCM122 Engine 15 DOL PEDAL Connector 46 3 Tripminder Module DFCM Horn Relay Way 2 INTRUMENT Water In Fuel Probe CTRL CTO BE 1 7 After Market CLUSTER M A eee ee ee 7 TPO Circuits ABS Module sc gt B 1 oa PTO P131 U137 Only Z i i VSS i Pressure Ctrl i 3_ CANIH Starter Motor I Solenoid 1 13 i 14 CAN 1L Public CAN CRUISE CONTROL l EBS Data Bus n i Pressure Ctrl l 27 N C Solenoid 2 Sa SCCS RESUME H ser aoc COAST E i N SCCSRTN HOFF lt 2200 cdo 120 Horn Switch a l bhaa CSEGND Type 6 Solenoid 3 PCM122 A ieee REECE EE oe EES O A RT Siete Be eee 7 TSPC z 24 Way FR ur Pressure Ctrl 12A650 Transmission 5R110 Transmission Wiring Assem
18. Engine Coolant Temperature Sensor FICM Fuel Injection Control Module Fuel Quantity Timing and Control Malfunction Engine Coolant Temperature Analog Voltage Voltage 40 4 32 68 77 104 140 212 248 284 302 Temperature Deg F Indicator Lamp NS PR Electro Viscous Fan Clutch L COO nn O Glow Plug 5 Control Module F c Y ECT Engine Coolant Temp The ECT sensor is a two 2 wire thermistor sensor The PCM supplies a 5 volt reference signal which the ECT sensor uses to produce an analog voltage The ECT sensor changes resistance when exposed to different temperatures When the temperature of the coolant decreases the resistance of the thermistor increases and the signal voltage increases 49 State Only 108 e When the temperature of the coolant increases the resistance of the thermistor decreases and the signal voltage decreases 94 ELECTRICAL COMPONENTS Exhaust Gas Recirculation Valve Position Sensor FICM Fuel Injection Control Module gt iS CE EGR Position Control Valve Powertrain Control Module Fuel Quantity Timing and Control Malfunction Indicator Lamp EGR Position vs Output Voltage N 0 gt al 0 1 2 3 4 5 _ Average Pintle Position mm VGT 0 100 Duty Cycle Control Valve 109 EGRVP Exhaust Gas Recirculation Valve Position The EGRVP sensor is
19. NPT 15 20 4 1 2 NPT 25 34 0 3 4 NPT 30 40 8 e All Figures on next page O 85 SPECIAL TORQUE CHART Intake Side 3 11 aL a a DA CIC A 3 6 2 CES Exhaust Side Figure A Cylinder Head Bolts e Step 1 Torque the M14 1 10 cylinder head bolts to 65 Ibf ft 88 Nm in the numerical sequence shown e Step 2 Torque the M14 cylinder head bolts 1 3 5 7 amp 9 to 85 Ibf ft 115 Nm in the numerical sequence shown e Step 3 Tighten the M14 cylinder head bolts an additional 90 clockwise in the numerical sequence shown e Step 4 Tighten the M14 cylinder head bolts an additional 90 clockwise in the numerical sequence shown e Step 5 Tighten the M14 cylinder head bolts an additional 90 clockwise in the numerical sequence shown e Step 6 Torque the M8 11 15 cylinder head bolts to 18 Ibf ft 24 Nm in the numerical sequence shown e Final Step Torque the M8 cylinder head bolts to 24 Ibf ft 32 Nm in the numerical sequence shown e Note Always use new head bolts Figure B Flywheel Bolts e Step 1 Torque the bolts to 1 5 Ibf ft 1 4 7 Nm in the numerical sequence shown above e Final step Torque the bolts to 69 Ibf ft 94 Nm in the numerical sequence shown above 86 SPECIAL TORQUE CHART 2 4 1 6 a Y e ae High Pressure Oil Rail Bolts e Step 1 Install bolts 1 2 and 3 finger tight i mn Figure C e Step 2 Press rail down until seated e Fi
20. wiring harness via a glow plug buss bar e The glow plug buss bar has four connectors attached to a single metal rail e The entire rail must be removed to gain access to any of the glow plugs on that bank 67 ELECTRICAL COMPONENTS Glow Plug System Diagnostics e One way to verify diagnostic data from the GPCM is to measure the amperage draw with an inductive amp probe INDUCTIVE AMP METER e Once the glow plug system has been commanded on by the PCM when engine temperature is warm you may need to trick the system into a cold condition for about 40 sec the glow plug amperage should be stable Each glow plug should draw between 10 12 amps e When testing the glow plug system it is best to measure one bank of glow plugs at a time The bank with the lower current draw would be the bank with the bad glow plug and or wiring concerns GLOW PLUG WIRING 130 68 UNIQUE SERVICE PROCEDURES Oil Filter Replacement e First loosen the oil filter cap which will open the oil filter drain and allow the oil from the filter housing to drain into the crankcase e Drain the oil from the oil pan e After all of the oil has drained from the oil pan remove the oil filter and discard it in the appropriate location e Note The oil filter snaps into the oil filter lid e Install the new oil filter element and tighten the oil filter cap to the recommended torque This will close the oil filter drain
21. 3 f Tripminder Module DFCM Horn Relay ET INTRUMENT Water In Fuel Probe CTRL 5 CLUSTER 1 4 After Market omoomoomeomoomeomeomeomeomee Crei ABS Module 79 9 A r gt PTO P131 U137 Only S O i y vss H Pressure Ctrl i CANTH CRUISE CONTROL u i E CANIL Public CAN H e cani UY 27 WT sccs Sane SAE o Solenoid 2 OFF 2200 680 Horn Switch H 24 Ohms Ohms H Pressure Ctrl 0 Visteon Les Yes PCM122 pe a E e 7 24 Way eer E Pressure Ctrl H 12A650 GH Transmission 5R110 Transmission Wiring Assembly Solenoid 4 i Module PV Connector 7 ZE PCA Pressure Ctrl H hoe Solenoid 5 i eco i 12 PCD Clutch Ctrl i Solenoid e e J SS UT U Mm In wI gt io Pron mee mee mm UU mem mer me moomoo mer mer msm Back UP Lamp Relay Control U an O WR ff MES els alel Fle le FR Bh U 1 O _ U a m ao 00 lm fm DIA Bel 3 z ofa e BPWR i LH BKP RH BKP m e Lamp Lamp runs i 0 0 E A PA AAA ss gt LA OSS E GEM 4x4 Module SS KEYPWR s C3 Pocket CM122 Trans Connector 30 Way TILL 93 DIAGNOSTIC CODES C Continuous Operation MIL Malfunction Indicator Light Illuminates O Self Test Key On Engine Off KOEO A Tow Haul Light flashes R Self Test Key On Engine Running KOER Assigned but not used
22. 81 Carryover 74 cooler 24 housing 24 Filter 25 Base 24 25 Replacement 69 Pan 22 Pressure Regulator 23 pump 23 Removal 77 Reservoir 25 26 Screen 25 Overview 6 P PCM Powertrain Control Module 66 Pick up tube 23 Plunger 44 Power or ground issues 80 101 INDEX R Rear Geartrain 14 Relative compression test 81 Rocker Arms 72 Rocker carrier 14 Removal 72 Rocker fulcrums 72 S Sensors overview 49 Single mass flywheel 15 Specifications 7 Stages of injection 45 y Table of contents 3 Turbocharger Oil drain tube 26 Removal 75 Oil supply 26 Removal 74 V VGT Variable Geometry Turbocharger Compressor 34 Control valve 35 Flow 35 Features 34 Turbine 34 Vanes closed 36 Vanes open 34 Vanes partially closed 36 VGTCV Variable Geometry Turbocharger Control Valve 65 W Water pump 19 102 103 104 2002 International Truck and Engine Corporation Printed in the U S A
23. AUSTRALIAN ADA REGULA THE EHGIME 65 ALSO CERTIFIED FOR SALE IN CALIFORNIA IN MEW VEHICLES RATED ABOVE 14 000 ran Dr AND IS CEATMFIED TO OPERATE ON MESEL FUEL THIS ENGINE CE MOTEUR A ETE PFINCIFALEMENT CONCU EM TANT OUUN MOTEUR DIESEL A DE GAMME LEGERE ET EST CONFORME ALIX RE E U ET CAMADSENS DE LANMEE DE MODELE 2001 CEATIFIE anil ETRE rg DUN Pav AL GELA D LH ETE E POUA FONCTION L CARBURANT DIESEL CE Me MOTEUR EST EXEMPTE DE LEXICENCE DBD 1 COMPONENT LOCATIONS Front of Engine 1 Thermostat 2 Fuel Inlets on Cylinder Heads 3 Fuel Pressure Regulator 4 ECT Sensor 5 EGR Throttle Actuator If Equipped Left Front of Engine 1 Fuel Supply 2 Fuel Return 3 EBP Sensor and Tube 4 Upper Oil Pan 5 Secondary Fuel Filter 6 EGR Throttle Position Sensor If Equipped aay pl id EN sa ti ha a 1 10 OO COMPONENT LOCATIONS Left of Engine 1 FICM 2 CMP Sensor 3 Oil Level Gauge 4 Crankcase Ventilation Left Rear of Engine 1 Rocker Arm Carrier 2 Bed Plate 3 Glow Plug Buss Bar 10 COMPONENT LOCATIONS Rear of Engine 1 Exhaust Expansion Joints 2 Heat Shields 3 Lifting Eye 4 Serial Number 5 ICP Sensor amp IPR Behind ICP Right Rear of Engine 1 Block Heater 2 Turbine Outlet 3 Exhaust Connection to EGR Cooler 4 Exhaust Expansion Joint 11 COMPONENT LOCATIONS Right Side of Engine 1 CKP Sensor 2 Glow Plug
24. 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 0L POWER STROKE TABLE OF CONTENTS OVERVIEW o o o NN 6 Features o oooocoonoo o ee 6 Horsepower amp Torque o o oo oo
25. Control Module Right Front of Engine 1 Heater Return 2 EGR Throttle Actuator 12 COMPONENT LOCATIONS Top of Engine 1 Oil Filter 2 Turbocharger Oil Supply Line 3 EVRT VGT Control Valve 4 Injector Connectors 5 Secondary Fuel Filter 6 EGR Cooler Coolant Deaeration Port N Top of Engine 1 EGR Valve 2 EGR Cooler 3 Turbocharger Compressor Outlet 4 AT2 Sensor 5 EOP Switch 6 EOT Sensor 13 6 0L POWER STROKE FEATURES Rocker Carrier e The aluminum rocker arm carrier is mounted on top of the cylinder head and is held in place by the cylinder head bolts e The rocker arm carrier provides the mounting location for all of the rocker fulcrums e The carrier also provides the connector pass through for the injector and glow plug AA lle Cylinder Head e The 6 0L POWER STROKE uses a four 4 valve per cylinder head design to increase air flow and efficiency e For identification the exhaust valves are smaller than the intake valves Rear Geartrain e The geartrain for the crankshaft camshaft and high pressure pump are located in the rear of the engine under the rear cover e This allows the high pressure pump to be mounted inside the engine and also reduces geartrain noise 14 ROCK E Ref afi w 1 ME a VOS ies Kir See iz Thuan T wr e a gt Ca r I 1 1 dl 19 6 0L POWER STROKE FEATURES STARTER RING RING OF BOLTS
26. EGR Cooler Removal amp Installation e Before removing the EGR cooler you must first drain the coolant from the cooling system e To disconnect the hose that supplies coolant to the EGR cooler rotate it and pull till the tabs release e Both the inlet and outlet for exhaust gasses are sealed with metal gaskets e The coolant connections are sealed with O rings AA Lt Turbocharger Oil Supply Removal e Use tool 303 755 to remove the oil feed to the turbocharger that is connected to the oil filter base e The connection at the turbocharger is a bolted flange and is sealed with a gasket om SUPPLY TUBE RN a tt 7 fees 147 Crankcase Ventilation Removal Oil COMPRESSOR Carryover INLET HOSE e To disconnect the crankcase ventilation tube T NE SAS e from the engine remove the air inlet tube from the compressor inlet and rotate the vent counter clockwise until it releases e Note Since the 6 0L POWER STROKE uses a closed crankcase ventilation system it is normal to see oil carry over in the intake air system 74 UNIQUE SERVICE PROCEDURES Turbocharger Oil Drain Tube Removal e The turbocharger oil drain is located under the turbocharger and is sealed with o rings e To remove the drain tube pull it forward out of the high pressure pump cover AAN Intake Manifold e When reinstalling the intake manifold the locating tabs on the intake manifold gasket should face up and towa
27. Filter An oil filter that requires only the element be replaced and not the housing CAN A communication protocol for data transfer between the con trol modules CKP Crankshaft Position Sensor A magnetic pickup sensor that creates a sine wave voltage when the timing wheel on the crankshaft breaks its magnetic field The CKP determines crankshaft position and speed Closed Crankcase Breather A ventilation system that recirculates crankcase vapors into the intake air system CMP Camshaft Position Sensor A magnetic pickup sensor that creates a sine wave voltage when a peg on the camshaft breaks its magnetic field The CMP determines which cycle the piston is in compression or exhaust Combination Fuel Pump Power Steering Pump A fuel pump and power steering pump that are made into one unit and driven off of the rear gear train Digital Fuel Injection A fuel injection system that uses both an open and close signal to control fuel injectors Dual Timing System A timing System that uses both a CKP and CMP sensors to determine engine speed and rotational position DVOM Digital Volt Ohm Meter A meter that uses a digital display to indicate a measured value Preferred for use on microprocessor systems because a DVOM has a very high internal impedance and will not load down the circuit being measured PCM Powertrain Control Module The housing which contains the micro computer Vref regulator input conditioners and output driv
28. PCM e FICM e Glow plug System Sensor Overview PCM Powertrain Control Module CMP CKP EP EOT Sensors Overview The PCM sends a Vref of 5 0 volts to the engine sensors except for CMP and CKP which generate voltage through the collapse of a magnetic field The PCM uses 5 volts as the reference voltage to maintain consistency throughout all operating conditions The Vref is conditioned by the sensors then returned to the PCM for use in determining the fueling strategy Generation Il Electrical Components Overview e The PCM uses information from the sensors to decide which commands to send to the FICM the actuators and the glow plug system 103 49 ELECTRICAL COMPONENTS Accelerator Position Sensor Three Track Pedal FICM Fuel Injection Control Module Powertrain Control Module Fuel Quantity Timing and Control Three Track AP Coorilation 5 APP2 m APP3 cmo 4 i oo cal cam Allen I tol 3 E LJ E MAA Bl Tol 7 mei Malfunction ewe Indicator Lamp an Closed Full EGR VGT IPR Throttle Throttle Position Throttle Control Control Injection Pressure Valve Valve Regulator 104 AP Accelerator Pedal Position e The three track pedal is a safety feature The three track pedal takes The AP Accelerator Pedal is a
29. PCM failed to activate during KOER switc test cy RY Clutch Switch Input Circuit KOER switch test Open short circuit switch PCM failed to activate during KOER switc test jii IO R OBD Systems Readiness Test Not Complete Drive cycle is not complete R KOER not able to complete KOER aborted Conditions not met A C Parking Brake Clutch PRNDL EOT ETC O R Water in Fuel Indicator Circuit E falt in circuit Faulty sensor Open or Short in circuit C O R Generator 2 Control Circuit i aii 10 i 184 IR Generator 2 Control Circuit High Pl Engine Oil Temperature Sensor Out Of Self Test ooo not warm enough to run KOEO CCT aborts test Engine not warm enough leaking themostat circuit failure Range Theft Detected Vehicle Immobilized lal iis KOER Injector Control Pressure Regulator Oa RE ER Ct failure Aborts KOER CCT test See codes P2284 P2285 P2286 P2288 P2623 FE FICM Supply Voltage Circuit Low IDM detects logic power low less than 7 volts Low batteries loose connections resistance in circuit defective relay R FICM Supply Voltage Circuit High IDM detects excessive voltage greater than 16 volts Charging system fault IR System Voltage Out Of Self Test Range PO Voltage too high or low for glow plug monitor test 3 Exhaust Gas Recirculation Flow Out Of Self Test EGRC output circuit check enaine off test onlv EGR Control circuit onen short to Vref Vbat around defective coil P14
30. RPM 325 3300 RPM Peak Torque RPM 560 2000 RPM Engine Rotation Facing Flywheel Counter Clockwise Combustion System Digital Direct Injection Total Engine Weight auto with oil 966 Ib 438 kg Coolant Flow 74 7 gal min 282 8 L min 3300 RPM Air Flow RPM 732 CFM 20 7 m3 min 3300 RPM Exhaust Flow RPM 1499 CFM 42 4 m3 min 3300 RPM Oil Flow RPM 18 5 gal min 70 L min 3300 RPM Cooling System Capacity engine only 11 1 gts 10 5 L Lube System Capacity including filter 15 qts 14 2 L Firing Order 1 2 7 3 4 5 6 8 Specifications L Front R The 6 0L Power Stroke engine is a totally new engine design that will provide improved performance and cleaner emissions e The cylinders of the 6 0L Power Stroke are numbered from the front on the right side 1 3 5 7 and from the front on the left side 2 4 6 8 OOO OOO Engine Serial Number e The engine serial number is located on the left rear corner of the crankcase e The engine serial number identifies the engine family build location and the sequential build number e 6 0 is the engine family identifier e HU2U is a manufacturing designator e 6000173 is a sequential build number Serial Number FICM Calibration Label e Another location for the engine serial number is a label on the FICM Fuel Injection Control Module e The engine serial number label also states the build location and build date of the engine
31. Secondary Circuit High Voltage present at the Fuel Pump monitor circuit when it has Indicates short to power sticking relay NOT been commanded on for more than 1 second P0236 C Turbo Super Charger Boost Sensor A Circuit Default inferred MAP low power slow acceleration greater MAP sensor plugged defective sensor Range Performance than 120kpa 2 7 PSI at low idle P0238 Turbo Super Charger Boost Sensor A Circuit High Default inferred MAP low power slow acceleration MAP MAP circuit short to Vref or Vbat defective sensor voltage is greater than 4 91 volts IR Cylinder 1 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil R Cylinder 2 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil R Cylinder 2 Injector Circuit High FICM detected an open injector circuit Injector circuit open defective coil R Cylinder 3 Injector Circuit High FICM detected an open injector circuit Injector circuit open defective coil R Cylinder 4 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil R Cylinder 5 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil R Cylinder 5 Injector Circuit High FICM detected an open injector circuit Injector circuit open
32. The oil filter element snaps into the oil filter lid Note The oil filter lid should be removed before draining the oil from the oil pan so that the oil can drain from the filter housing into the oil pan AAN Oil Reservoir amp Screen The oil reservoir for the high pressure oil pump is located under the oil cooler in the valley of the engine The oil reservoir holds about 1at of oil A screen in the oil reservoir catches any large debris that may be in the oil before it gets to the high pressure oil pump 25 LUBRICATION SYSTEM Oil Flow at Oil Reservoir There are five 5 oil passages and one coolant passage near the oil reservoir in the crankcase Two 2 of the oil passages are for oil feed to the crankcase for lubrication One 1 is for oil feed to the oil cooler and the other oil passage is oil filter drain to the oil pan The passage in the bottom of the reservoir is for oil feed to the high pressure oil pump The coolant passage is for coolant feed from the water pump to the oil cooler Turbocharger Oil Supply amp VGT Control Oil is supplied to the turbocharger from the oil filter base via a flexible steel braided oil line to the top of the turbocharger The oil line is connected to the oil filter base using a snap to connect fitting and requires a special tool for removal This line is also the feed to the VGT control valve 26 Turbocharger Oil Drain Tube The VGT uses oil to control
33. a three 3 wire potentiometer type sensor The PCM supplies a 5 volt reference voltage that the EGRVP uses to produce a linear analog voltage that indicates the amount of movement of the valve The PCM monitors EGRP as the engine is operating to modulate the EGR valve This is a closed loop function which means that the PCM continuously monitors the EGRVP to ensure proper valve operation ELECTRICAL COMPONENTS E 56 Vehicle Gauge Reading Gauge Reading Normal 0 5 7 12 18 24 30 36 42 48 54 60 66 72 78 Actual Oil Pressure PSI EOP Engine Oil Pressure Switch The EOP Engine Oil Pressure Switch is a switch that closes a circuit to ground after engine oil pressure reaches approximately 5 7psi This switch controls the oil pressure gauge on the instrument panel When pressure is above 7psi the gauge will read normal and if the pressure drops below 6 psi the gauge will show 0 The information from the switch is not fed back to the PCM in any way and is to be used as a reference only Engine Oil Pressure Switch INTRUMENT CLUSTER 110 ELECTRICAL COMPONENTS Powertrain Control Module Engine Oil Temperature Sensor Engine Oil Temperature Analog Voltage TT 5 p R o 3 S S 2 MA 1 Ww 7 i om 40 4 32 68 77 104 140 212 248 284 302 ES EGR IPR Temperature Deg F EOT Engine Oil Temperature e The EOT sensor is a two 2 wire thermistor ty
34. and VGT control ELECTRICAL COMPONENTS Crankshaft Position Sensor FICM Fuel Injection Control Module Powertrain Control Module Fuel Quantity Timing CKP and Control CKP Out Malfunction i i i Indicator Lamp WIDE SLOT 106 CKP Crankshaft Position end of the sensor creates a signal the relates to u crankshaft speed and position The crankshaft position signal e Crankshaft speed is derived from relative to TDC Top Dead Center source is a magnetic pickup sensor the frequency of the CKP sensor The CMP creates a signal relative mounted in the right front side of signal to which stroke the piston is the engine block currently on compression or e Crankshaft position can be exhaust e The sensor reacts to a target wheel determined by the sycronization of positioned on the crankshaft The the CMP peg signal to the CKP target wheel is a 60 minus 2 tooth minus 2 slot signal steel disk with 58 evenly spaced teeth and a slot that s width is e Diagnostic information on the CKP equivalent to removing 2 teeth input signal is obtained by minus 2 slot that is the SYNC performing accuracy checks on fre gap quency and or duty cycle with soft ware strategies The sensor will produce pulses for each tooth edge that breaks the e The PCM needs both the CKP and magnetic field created by the CMP signal to calculate engine permanent magnet that is in the speed and position The CKP
35. and fresh air are mixed e After mixing with crankcase vapors the fresh air mixture is drawn into the turbocharger compressor where it is compressed and sent to the charge air cooler CAC Throttle Plate Charge Air Cooler EGR Cooler Exhaust Pressure Sensor The CAC condenses the air by cooling it then the air returns to the engine through the intake manifold There is a throttle body on the intake manifold The throttle body may or may not have a throttle plate For 2003 25 the throttle plate will not be active in the pcm strategy The intake manifold directs the air to the intake ports of the cylinder heads The burned air fuel mixture is pushed out of the cylinder into the exhaust manifold which collects the exhaust gases and routes them to the turbocharger turbine wheel The exhaust up pipe connected to the passenger side exhaust 32 Compressor Outlet Air Filter Mass Air Flow Sensor amp Air Intake Sensor 1 Compressor a Turbine Inlet L ef e gt a o o a Control Valve Turbo Outlet to Exhaust Throttle Plate may not be present 62 manifold has a passage that connects it to the exhaust gas recirculation EGR cooler e The exhaust gasses cooled by the EGR cooler are sent to the EGR valve in the intake manifold e The EGR valve controls the flow of exhaust gases into the intake system w
36. before entering the intake manifold lc ee CARE Sie P _ 33 AIR MANAGEMENT SYSTEM VGT Features The turbocharger for the 6 0L Power Stroke engine is designed to provide boost control at low and high speeds for improved throttle response The Variable Geometry Turbocharger VGT is electronically controlled and hydraulically actuated The VGT may also be referred to as EVRT When the vanes of the turbocharger are closed the engine will have a higher exhaust back pressure and create more heat which will in turn warm the engine faster in cold ambient conditions VGT Compressor The compressor on the VGT is similar to the compressor on a conventional turbocharger The compressor wheel is connected to the turbine via a common shaft 34 VGT Turbine The VGT uses a turbine wheel that is similar to a conventional turbocharger but the turbine housing has changed The turbine housing contains vanes that control the effective size of the housing These vanes are hydraulically actuated and electronically controlled VGT Turbocharger Features e Electronically Controlled Hydraulically actuated e Low amp High Engine Speed Boost Control e Incorporates Fast Warm Up Device AIR MANAGEMENT SYSTEM VGT Control Valve VGT COIL OIL DRAIN TO PAN OIL TO CLOSE SIDE OF PISTON OIL SUPPLY CAM FOLLOWER OIL TO OPEN SIDE OF PISTON 69 VGT Control Valve KOEO Turbo Va
37. in EGR cooler flange studs see note 1 0 0o oocccccoccccconon 10 Ibf ft EGR cooler support see note 1 ccc cece eee eee eee eens 23 Ibf ft IO O IS ee 10 Ibf ft Engine coolant temperature sensor ECT ccocccccococnr 106 Ibf in Engine oil pressure switch EOP occococccccccnrno 106 Ibf in Exhaust manifold flange to up pipe see note 2 20 Ibf ft Exhaust manifold see note 2 0 cccccccoccococconnnrnrr 28 Ibf ft Exhaust pressure EP sensor bracket ccceeeeeeeeeees 106 Ibf in Exhaust pressure EP sensor zusursennnnnnnnnnnnennn nun nenn 106 Ibf in Exhaust pressure EP tube nuts see note 2 22 Ibf ft Exhaust up pipe to EGR cooler v band oc oocoooooo 20 Ibf ft Exhaust up pipe coupling on right side cococococo 20 Ibf ft Flywheel bolts see figure B zzsussennennn nenn nennen un nenn 69 Ibf ft ee 18 Ibf ft Fuel check valve banjo bolt cece cece e eee eee eens 28 Ibf ft Fuel filter supply and return lines cece cece eee ees 32 Ibf ft Fuel filter supply to head lines cece eee e cece eee ees 19 Ibf ft O aan nc nano 24 lbf ft eee ee 20 Ibf ft A 14 Ibf ft Glow plug control module GPCM zzussennnnennn nun nenn 71 Ibf in Heat shield for intake manifold M6 nut oooooooooooo 96 Ibf in Heat shield bolts for rear M6 thread forming
38. the high pressure pump and the oil passages in the crankcase e The coolant is directed from the front of the crankcase to the front of the oil cooler It then passes through the oil cooler and cools the oil As the coolant exits the rear of the oil cooler it is directed to the EGR cooler FI 24 LUBRICATION SYSTEM OIL TEMPERATURE SENSOR D BD NEOWURNE gt 0 u jim y i o 2 OIL FILTER BYPAS a j p ad OIL FILTER DRAIN ANTI DRAIN BACK OIL COOLER BYPASS 45 OIL FILTER ELEMENT e i Ni Oil Filter Base amp Valves The oil filter base routes oil to the oil filter engine oil pressure switch EOP engine oil temperature sensor EOT and the turbocharger oil feed The oil filter base also houses the anti drain back check valve that keeps oil in the oil filter assembly after the engine is shut off The oil cooler bypass is in the filter base and opens at a pressure differential of 25 psi The oil filter bypass is in the oil filter stand pipe and opens at a pressure differential of 20 psi There is an oil drain for the filter housing to drain oil from the housing during an oil change A Oil Filter The 6 0L POWER STROKE uses a cartridge style oil filter located on the top of the engine When the oil filter is removed the oil filter housing drain valve is automatically opened to drain most of the oil from the housing
39. the place of the Idle Validation three track pedal The AP Switch allowing for limited system incorporates three potentiometers failure and still maintaining Through out the movement of the performance AP the resistance values of the three potentiometers must agree During the movement of the AP if one of the three potentiometer readings do not agree the check engine light will illuminate and the vehicle will continue to perform as normal If two signals from the AP are lost the PCM will allow the engine to idle only and illuminate the check engine light 50 ELECTRICAL COMPONENTS Barometric Pressure Sensor FICM Fuel Injection Control Module Powertrain Control Module Fuel Quantity Timing and Control Malfunction Indicator Lamp Barometric Pressure Sensor Analog Voltage 5 4 5 4 d 3 3 5 3 ETE IE 2 IL IE O 12500 10000 7500 5000 2500 0 2500 NS i AE er N AY EGR bas S Glow Pl i Control un Elevation feet above sea level Control Control Module LO Valve alve 105 Baro Barometric Pressure e The BP sensor is a three 3 wire variable capacitance sensor e The PCM supplies a 5 volt reference signal which the BP sensor uses to produce a linear analog voltage signal that indicates pressure e The primary function of the BP sensor is to provide altitude information so that the PCM can adjust timing fuel quantity glow plug on time
40. 08 95 DIAGNOSTIC CODES P1703 O R Brake Switch Out Of Self Test Range P1705 Transmission Range Circuit Not Indicating Not in O a during KOEO or KOER Operator error circuit failure faulty sensor PCM Park Neutral During Self Test P1725 R Insufficent engine speed increase during self test P1726 R Insufficent engine speed decrease during self test AA Range Performance PR ip TT Input A a Input A Intermittent A P Range Performance lr a Input Hal nn Input lr P Intermittent PE PR A Range Performance Pee PR Itt Input ee PR fip o a roson Sorsom orowan Input ja a E Intermittent eee O S een Mechanical exhaust restriction SP dd AO ee exhaust restriction exhaust leaks EA AA AAA eN A era zT Range Performance difference of 362psi 2 5mpa AAA Default open loop control underrun at idle ICP is less than ICP circuit short to ground or open defective sensor 0 04 volts ren Default open loop control underrun at idle ICP is greater ICP circuit short Vref or Vbat defective sensor than 4 91 volts A A ON 3675psi 25mpa P2289 C O Injector Control Pressure Too High Engine Off Default inferred ICP KOEO ICP is greater than ICP signal ground circuit open defective sensor P2290 C O Injector Control Pressure Too Low Default inferred ICP is used ICP is below desired pressure See diagnostic manual ICP system
41. 6 0L DIT Direct Injection Turboc charged Diesel Engine 2003 25 F Series Super Duty FORWARD This publication is intended to provide technicians and service personnel with an overview of technical advancements in the 6 0L 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 Use safety stands whenever a procedure requires you to be under the vehicle
42. 758 with engine at 70 C 170 F minimum Block breather tube on left valve cover e Measure at WOT with no load at 3 000 RPM Instrument Spec Measurement 0 60 H20 8 H20 MAX Magnehelic FE If more than 8 H20 refer to base engine in Shop Manual 15 Oil Aeration Test Run engine at 3000 RPM for 1 minute Take oil sample from the Oil Pressure Switch port at idle e Inspect sample for presence of air bubbles NEN Excessive oil aeration can be caused by depleated oil additives pick up tube leak front cover seal leak or upper pan seal leak Note If performance concern still exists refer to Enhanced Injector Diagnostics in this section See PC ED manual Section 4A for more detail on all of the above test steps When troubleshooting a Hard Start No Start or Performance concern this form must be filled out to the point of repair and returned to receive warranty credit and diagnostic time for the following parts Fuel Injectors 9E527 regulator injection control pressure 9C968 pump assembly high pressure oil 9A543 turbo charger assembly pedestal 6K684 fuel pump 9350 FICM 12B599 and PCM EEC 12A650 Labor operations listed more than once are a continuation of the diagnostic procedure and should be claimed only once What problems were found and what repairs were performed List Part Name Number and Serial Number of parts replaced 89 WIRING DIAGRAM SINGLE ALT
43. Chassis Inspection e Verify that there are no fluid or pressure leaks e Inspect all wire connections for damage e Inspect MAP hose intercooler hose and manifolds for leaks Fuel Oil Coolant Electrical Hoses Leaks Method ace PF Sufficient Clean Fuel e Check if WATER IN FUEL indicator has been illuminated Drain sample from fuel control module housing e Cetane rating between 40 50 is recommended for optimum performance DEE Check Engine Oil Level Check for contaminants fuel coolant e Correct Grade Viscosity e Miles hours on oil correct level om Perform KOEO On Demand Test e Use the scan tool DTCs set during this test are current faults Diagnostic eca Retrieve Continuous DTC s e Use the scan tool DTCs retrieved during this test are historical faults a Trouble Codes KOEO Injector Electrical Self Test e Use the scan tool All injectors will momentarily click then individual injectors will click in sequence 1 though 8 Injector Trouble Codes If self test codes are retrieved go to appropriate PPT Intake Restriction e Check filter minder switch indicator e Measure vacuum on clean side of air inlet system at WOT with magnehelic gauge Instrument Spec Check Magnehelic Filter Minder 2 25 H20 8 EGR Position e Perform with key on engine off e Use scan tool to command Output State Control for EGR e Monito
44. Cover e The high pressure pump is installed inside the crankcase e The pump is a seven 7 piston swash plate style pump that is driven off of the rear gear train e Minor leakage from the pump will not create external oil leaks e Both banks of cylinders are supplied oil through one 1 pump outlet IPR Injection Control Pressure Regulator amp ICP Injection Control Pressure Sensor e The IPR and ICP are both installed into the high pressure pump cover beneath the turbocharger turbine inlet pipes High Pressure Oil Rail with AWA Feature e The high pressure oil rail has special AWA Acoustic Wave Attenuation features to dampen hydraulic noises e To accomplish this an AWA fitting is placed in the center of the high pressure oil rail and two specially designed end caps are used 42 HIGH PRESSURE PUMP COVER HIGH FRESSURE PUMP CIDER IY KENT OORE I zu DISCHARGE LINE FUEL MANAGEMENT SYSTEM e Digital Valve e 48 Volts e 20 Amps coil e Short Coil On Times e Self extracting hold down clamp INTERNAL O RING i A AS INJECTOR COILS E iE y COPPER GASKET i 94 HIGH PRESSURE OIL IN em NN D COIL NN A AAN UY ENANA COIL m x ow A gt Wise Se N q A N BS UN SPOOL VALVE gl 92 Fuel Injector Features e The injector uses two 2 48 volt 20 amp coils to control a spool valve that directs oil flow in and out of the inject
45. ET 138 Injector O ring Replacement cont To install the copper gasket to the injector tip use a twelve 12 point 9mm deep well socket so that pressure is applied evenly around the gasket during installation Note If the gasket is mis shaped or damaged during installation it must be replaced The internal upper o ring is not removable If the internal o ring is leaking the entire injector assembly must be replaced A Injector Installation Before installing the injector the o rings should be lubricated with clean engine oil Place the injector into the bore with the injector hold down on the injector Note Make sure that the copper washer does not fall off the tip of the injector during installation engine damage could result if the gasket is not in place Using the hold down bolt to seat the injector in the bore slowly tighten the bolt to the specified torque Note Again do not use air electric tools to install injectors A Injector Installation cont Before installing the high pressure oil rail to the rocker carrier lubricate the internal o ring that the oil rail jumper tube contacts Place the oil rail over the injectors and seat it by hand The oil rail should then be tightened as specified Note Anytime injectors are changed Ford lubricity additive should be added to the fuel filter and fuel tank 71 UNIQUE SERVICE PROCEDURES Cylinder Head Rocker Carrier Removal Befor
46. FCM draws fuel from the fuel tank and through a 10 micron fuel filter The HFCM contains the fuel pump filter water separator water in fuel switch fuel drain fuel heater and diesel thermo recirculation valve DTRM The DTRM controls the flow of fuel returned from the secondary filter through the HFCM If the fuel being drawn from the fuel tank is cool then return fuel is recirculated into the pump if it is warm then return fuel is sent to the fuel tank DIESEL THERMO RECIRCULATION VALVE DTRM PRESSURE After the fuel is conditioned by the HFCM the clean pressurized fuel is sent to the secondary fuel filter assembly where particles larger than 4 micron are filtered out of the fuel The secondary filter assembly also regulates fuel pressure by releasing excess pressure via a return fuel line back to the HFCM It also has an orifice at the top of the housing in order to bleed air out of the housing and back to the fuel tank After the fuel flows through the secondary filter it is directed to the two 2 cylinder heads via fuel lines 28 FUEL REGULATION VALVE 60 5 PSI CRACKING CYLINDER HEAD RB LB oO D 1 O m A a 93 past the fuel check valves e The fuel is directed to the injectors via passages that are drilled into the cylinder heads Once the fuel has entered the head past the check valve it does not return to the fuel supply system This is
47. Indicator Lamp VGT Control Valve Fuel Quantity Timing 112 ELECTRICAL COMPONENTS g Intake Air Temperature Sensor 1 FICM Fuel Injection Control Module PCM Powertrain Control Module Fuel Quantity Timing and Control IAT 1 MAF Intake Air Temperature Sensor 1 Analog Voltage 5 4 9 3 S 2 Malfunction j Indicator Lamp 40 22 4 14 32 68 131 149 167 185 203 221 239 257 Temperature deg F 113 IAT1 Intake Air Temperature sions 1 l e The MAF IAT1 sensor is mounted in e The Intake Air Temperature IAT 1 the intake air piping after the air sensor is a two wire thermistor filter sensor that is located inside the Mass Air Flow MAF sensor e The PCM supplies a 5 volt reference signal which the IAT1 uses to produce an analog voltage that indicates the intake air temperature e The IAT1 sensor s primary function is to measure intake air temperature to control the timing and fuel rate when cold starting The continuous monitoring by the IAT1 sensor limits smoke emis ELECTRICAL COMPONENTS Powertrain Control Module FICM Fuel Injection Control Module Intake Air Temperature Sensor 2 IAT 2 Fuel Quantity Timing and Control Intake Air Temperature Sensor 2 Analog Voltage s Alba 4 Malfunction Indicator Lamp SA 3 2 2 WU 6 IT BGS CLASSES SISORSTESLSEE EGR Tempature Deg F Control Valve IAT2 I
48. NG DIAGRAM DUAL ALT 12 Way On Off Engine Connector Type 4 Ground FICM Power A C Relay PCM Power U O 7 Line Pressure Solenoid TU Q O am Relay Relay ae FP Relay Ignition Switch PWR module xy B KEYPWR _ _ _ _ JJJ A cana 8 Way On Off Engine Connector IO A A pa Ground u BAP INTRUMENT CLUSTER Visteon MAF MAR Regulator La FALL ILL KEYPWR Sense z z y 5 J1 C1 Pocket B 4 1 PCM122 Chassis 6 4 Connector 46 22 Sense To x 5 6 E m gt El 7 1 TOON ENI 46 OG pa n 14 1 23 S y a gt nn 11 19 f 3 4 27 2 Alternator A m y 7 Bu a gt Y z Aeus M ESPE 32 7 a Se p 3 45 44 i E 5 3 4 SS il yA 44 9 z ET UN Acpsw A y Be pee J 31 33 7 fve e E A E F __ 4 gt lu PS VE E E r Er a Ml MAERTN Zu Br p a J hu PES EEE p E feao E NN p a Te MAP ee A A Z Perr 4 eu y cent Ground a lt p EA 7 a 3 M vREE2 IA i B AOS HE IE A le g Pe a A T ilar d ral T W a c A gt Hl Tows To AC System 6 Z ah 36 f CRD n aKEYPWR Starter Relay 7 36 I KEYPWR CTRL Ignition Switch d io le gt VPWR A 20 18 BEE TRO THREE TRACK 2 JI PEDAL
49. OER DTC If pressure is above spec check fuel return lines for restriction If no restriction is present replace fuel pressure regulator valve 12a Low Idle Stability ICP Pressure e Check at low idle EOT above 70 C 170 F Monitor ICP and RPM with scan tool Spec 670 RPM Parameter 4 5 5 5 Mpa 3MPa 650 800 PSI 45 PSI Take reading before disconnecting ICP If engine RPM is unstable disconnect ICP sensor ICP will default If RPM is still unstable re connect sensor and go to 12b If RPM smoothes out the ICP sensor is at fault 12b Injection Pressure Regulator Test e Check at low idle EOT above 70 C 170 F e Monitor IPR with scan tool Spec 670 RPM If duty cycle is below MAX spec go to next step If duty cycle is above MAX spec check for system leak with procedure in Hard Start No Start section Test 10c 13 Boost Pressure Test e Carefully inspect intercooler tubes connections turbocharger connections and MAP hose for signs of damage or leaks e Perform boost test at 3300 RPM e Monitor MGP and RPM with scan tool Road Test select appropriate gear to obtain desired engine speed and full load on engine climbing hill or loaded truck 3300 RPM Parameter_ Spec PSIG Measurement 22 PSIG MIN If test fails low inspect turbo blades for damage 14 Crankcase Pressure Test e Measure at oil fill tube with 6 0L Crankcase Pressure Tester p n 303
50. The pump has an internal regulator that limits fuel pressure to 100psi e Fuel returning from the pressure regulator on the engine mounted fuel filter comes into the HFCM and a DTRM either allows the fuel to return to the tank or returns it to the unfiltered side of the fuel filter in the HFCM The DTRM starts to open recirculating fuel back into the pump at 80 F 27 C and is fully open at 50 F 10 C I O C 29 e A secondary fuel filter is mounted to the oil e The secondary filter is a 4 micron cartridge 30 FUEL SU J i ww mM Y j a 4 4 ER A A W 4 yl W Ae E W i A A a Y y a u W y A Y 4 T wv en Wi j Y en y Y en y A VA yA ww LW j A Y l a 3 gt t E W a Engine Mounted Fuel Filter filter housing style filter It also incorporates a fuel pressure regulator and an air bleed to allow air to escape after a filter change Fuel from the regulator is returned to the HFCM Fuel Pressure Regulator The fuel pressure regulator is mounted to the engine mounted fuel filter It regulates fuel pressure by routing unfiltered fuel from the filter housing to the HFCM via a spring loaded poppet style valve The cracking pressure pressure at which the valve begins to open of the valve is 60psi 5psi Actual fuel pressure may be above or below this specification Fuel Inlet Check Valves Each cylinder head
51. are routed into the EGR cooler from the exhaust up pipes at the rear of the engine The exhaust gasses are cooled by passing through metal tubes that are surrounded by engine coolant Depending on conditions the temperature drop across the cooler could be as much as 700 F The cooled gasses are then routed to the EGR valve that is mounted in the intake manifold O 37 AIR MANAGEMENT SYSTEM EGR Throttle e All 2003 25 6 0L Power Stroke engines are equipped with a throttle body e Some early versions also have a throttle plate in the throttle body Later versions will retain the throttle body but not the throttle plate e The throttle was designed to assist with EGR operation but later was determined unnecessary e The PCM software for controlling the throttle body was not added and the plate was removed e The throttle body may become operational for the 2004 model year e Note All engines have the wiring plugged into the throttle body and position sensor even if the throttle plate is not present ls Intake Manifold e The intake manifold on the 6 0L Power Stroke is made of aluminum and directs the flow of air to the intake ports in the cylinder heads e The Intake manifold provides a path for coolant from the EGR cooler to the front cover e There is a passage for EGR gasses to go to the EGR valve where they mix with compressed intake air e The manifold absolute pressure sensor MAP port and t
52. aults Refer to PC ED section 4 for detailed test procedures See PC ED manual Section 4A for more detail on all of the above test steps When troubleshooting a Hard Start No Start or Performance concern this form must be filled out to the point of repair and returned to receive warranty credit and diagnostic time for the following parts Fuel Injectors 9E527 regulator injection control pressure 9C968 pump assembly high pressure oil 9A543 turbo charger assembly pedestal 6K684 fuel pump 9350 FICM 12B599 and PCM EEC 12A650 Labor operations listed more than once are a continuation of the diagnostic procedure and should be claimed only once What problems were found and what repairs were performed List Part Name Number and Serial Number of parts replaced PERFORMANCE DIAGNOSTICS F Series Excursion Powerstroke 2003 25 6 0L Power Stroke Diesel Engine Diagnostic Guide NOTE IF CONCERN IS FOUND SERVICE AS CUSTOMER NAME REQUIRED IF THIS CORRECTS THE CONDITION IT IS NOT NECESSARY TO COMPLETE THE REMAINDER OF THE MODEL YEAR VEHICLE SERIAL NO VIN DIAGNOSTIC PROCEDURE CHASSIS STYLE Customer Concerns Please list in this box DEALER NAME 1863 CLAIM NUMBER P amp A CODE DATE ENGINE SERIAL NUMBER ODOMETER TYPE OF SERVICE VEHICLE GVW TRANSMISSION AMBIENT TEMPERATURE PERSONAL C COMMERCIAL L Visual Engine
53. bly Solenoid 4 Module re 20 Connector i 24 9 PCA do Pressure Ctrl ae PCB Solenoid 5 I 3 Era PCC i 11 PCD i 5 Converter f 12 4 Clutch Ctrl N a A PCE i z Solenoid i un l 14 POE 8 3 i y Line Pressure 2 PCG i 7 s i PSA T Solenoid 17 Ad a Eee Sees meses iS A il aan PSB I ET 2 Back UP Lamp 19 PSE i EHG TRS i TSS ISS oss Relay Control T PSD i 20 11 I NOTE Prize PSE aa 0 B i For clarity of 26 TFT 18 th int all 30 TSIGRTN a e print a 30_ VBPWR gez LHBKP RH BKP 1 21 l three FICM TR P i EN i Lamp Lamp 5 15 l connectors are ra TPWRGND l FE shown Piz TSS Bere en eS es 2 ee ISS together as 27 Ground one The pin 28_ numbers are color coded ro RLC red for X2 4 TRO N GEM 4x4 Module blue for X1 ae ae and black for a GiS X3 24 N C a GLIL N C x Hi C3 Pocket C M122 Trans Connector 30 Way 91 WIRING DIAGRAM DUAL ALT SENSORS CAM ICP EOT EC CRANK POSITION POSITION i 2fi 2h c A 2h 2h A Cc FREGD A n EGR Intake IPR VGT Actuator Throttle Position Actuator Actuator Actuator Orientation Looking into terminals on connector PURPLE V ini 48 VOLTS Lt BLUE V ref 5 VOLTS GREEN SIGNAL CIRCUIT Dk Blue D mmunication Link DCI RED 12 VOLTS V Batt Gold Plated Pins pa 2 Sg is oa O O 92 2 gt UO0U gt 00U EP Cylinder 2
54. called a dead end fuel system FUEL SUPPLY SYSTEM y HFCM Horizontal Fuel Conditioning FUEL RETURNA TANK Module E a BE e The HFCM is mounted to the frame rail on the drivers side e The HFCM is a single module that performs multiple tasks It heats fuel separates water from the fuel senses when water is present in the fuel filters particulates from the fuel creates fuel pressure needed to to supply fuel to the engine mounted fuel filter e ADTRM Diesel Thermo Recirculation Module is also part of the HFCM It recirculates fuel that returns from the engine mounted fuel filter back into the fuel filter instead of back to the tank which in cool fuel conditions HFCM Horizontal Fuel Conditioning Module Fuel Flow e Fuel is drawn into the HFCM from the fuel tank via a supply line If the temperature of the the fuel is below 50 F 10 C it is heated by the fuel heater The fuel heater shuts off at 80 F 27 C e After being heated fuel enters the filter housing via a one way check valve e Once in the filter housing water is separated from the fuel If large amounts of water are found in the fuel a sensor in the separator warns the operator of this condition by illuminating a light on the dash e Fuel is then drawn through the 10 micron fuel filter and into the fuel pump e Conditioned pressurized fuel is then supplied THROUGH FILTER INTO PUMP to the engine mounted fuel filter via a fuel supply line
55. ch as an injector remains energized Relative Compression Test A test that can be run with the WDS to measure compression of a cylinder relative to the other cylinders in the engine This test is accomplished by comparing the rom of the engine during each compression stroke GLOSSARY Rocker Arm Carrier A housing that the rocker arms and their fulcrums are mounted to Thermistor Sensor used to determine temperature A thermistor changes it s resistance value in relation to temperature change Increasing temperature results in decreasing resistance decreasing temperature results in increasing resistance The thermistor in conjunction with a current limiting resistor in the PCM forms a voltage divider that provides a voltage signal indicating temperature Since the top half of the voltage divider is the current limiting resistor and is internal to the PCM a thermistor sensor only has two connections signal return and ground Variable Capacitance Sensor A sensor that is used to determine pressure A variable Capacitance sensor changes it capacitance value in relation pressure change Increasing pressure results in a lower capacitance thus increasing return voltage Decreasing pressure results in a higher capacitance and a lower voltage Variable capacitance sensors are 3 wire sensors VBAT Battery voltage VGT Variable Geometry Turbocharger Could also be called EVRT A turbocharger that has a turbine housing that can chan
56. cian to disable one injector at a time and monitor pids to identify weak injectors e While disabling injectors watch the Mfdes pid The injector s that have the least effect on Mfdes while being disabled could be the weak injector 80 b b ems BATE CONN EKO i i p OFF ee Diab EDT 75 Morsa Er E 100 F HEOES Injector 1 Disable 164 GENERAL DIAGNOSTICS 5 INJECTOR OFF ALL INJECTORS ON 165 5 GLOW PLUG REMOVED GOOD ENGINE 166 NON AERATED OIL a i ee sa i x ii PA Hr Cylinder Balance Test The cylinder balance test is now available for the 6 0L Power Stroke The cylinder balance test measures the increase of engine RPM during each firing cycle It then compares the RPM of all cylinders to determine a weak cylinder Further testing should be done to verify the weak cylinder Relative compression Injector disable actual compression etc A Relative Compression Test The relative compression test is now available for the 6 0L Power Stroke The relative compression test measures engine RPM during each compression stroke while cranking the engine lt then compares the RPM of all of the cylinders to determine if there is a cylinder that is weaker than the rest Once a cylinder is determined to be weak a manual compression test should be run on that cylinder and a good cylinder to verify res
57. d torque to specifications VALVE UNIQUE SERVICE PROCEDURES Glow Plug Injector Sleeve Removal Place the tap part of tool 303 764 into the glow plug sleeve and cut threads into the sleeve Remove the tap and insert the puller part of tool 303 764 into the glow plug sleeve Turn the puller clockwise until the sleeve is removed Injector sleeve removal is simular to glow plug sleeve removal except that tool 303 768 is used Glow Plug Injector Sleeve Installation Instructions for injector and glow plug sleeves are similar so the instructions are combined First clean out any sealant from the bore before installing a new sleeve Apply sealant Loctite 620 green in color to the two 2 locations that the sleeve contacts the cylinder head Note Refer to service manual for proper location of sealant application Use the special tool tool 303 767 for injector sleeve or tool 303 763 for glow plug sleeve to drive the sleeve into its bore _ _ _ EGR Valve Removal To remove the EGR valve remove the two mounting screws from the intake manifold Rotate the valve so that the mounting tabs on the valve align with the EGR valve puller tool 303 760 Position the other two 2 legs of the puller on the bolt bosses of the intake manifold and turn the forcing screw clockwise When reinstalling the valve check the o rings for cuts and nicks 73 UNIQUE SERVICE PROCEDURES
58. d with the ignition switch in the ON position and the engine RUNNING 98 Main Power Relays Two Battery power relay switches for the ECM and IDM modules that are key power initiated and controlled by the corresponding powered module MAP Manifold Absolute Pressure A MAP sensor generates a digital frequency that indicates manifold boost pressure above atmospheric pressure The signal is created by switching action caused by manifold pressure of a diaphragm connected to a capacitor circuit in the sensor The digital frequency increases as pressure increases A MAP sensor has three connection signal return gnd MAP signal and Vref Misfire Detection Uses engine RPM changes during a firing cycle to determine a low contributing cylinder Modular Water Pump Is a water pump that uses the front cover as a housing and only the hub and impeller are replaceable Normally Closed Refers to a switch or a solenoid that is closed when no con trol or force is acting on it Normally Open Refers to a switch or a solenoid that is open when no control or force is acting on it POT Potentiometer Converts a mechanical motion to a voltage value Most often used to sense the position of a component This sensor works as a variable voltage divider The wiper arm is mechanically connected to the component desired to be sensed Potentiometers have three connections Vref signal out and ground Pulse Width The length of time an actuator su
59. defective coil R Cylinder 6 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil R Cylinder 6 Injector Circuit High FICM detected an open injector circuit Injector circuit open defective coil IR_ Cyli ircui R Cylinder 7 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil Cvlinder 7 Iniector Circuit Hiah FICM detected an open iniector circuit Iniector circuit open defective coil P0261 P0262 P0264 P0265 P0267 P0268 P0270 P0271 P0273 P0274 P0276 P0277 P0279 P0280 P0237 C Turbo Super Charger Boost Sensor A Circuit Low Default inferred MAP low power slow acceleration MAP MAP circuit short to ground or open defective sensor voltage is less than 0 039 volts Cylinder 1 Injector Circuit High FICM detected an open injector circuit Injector circuit open defective coil Cylinder 3 Injector Circuit Low FICM detected a short in an injector circuit to ground Injector circuit short to ground defective coil Cylinder 4 Injector Circuit High FICM detected an open injector circuit Injector circuit open defective coil 94 DIAGNOSTIC CODES P0341 C Camshaft Position Sensor A Circuit CMP ee intermittent Poor connection defective sensor electrical noise Range Performance Bank 1 or single sensor P0381 C Glow Plug Heater Indicator Circuit a Circuit Check Instrume
60. during crank check the FICM logic power feed to the FICM e To check powers and grounds to the FICM you can bring up the following pids on the WDS FICMVPWR FICM Vehicle Power battery voltage FICMMPWR FICM Main Power or output voltage approximately 48 volts FICMLPWR FICM Logic Power battery voltage 82 APPENDIX TABLE OF CONTENTS Torque Charts ee eee 84 Hard Start No Start Diagnostics 88 Performance Diagnostics 89 Wiring Diagrams ew ee ees 90 Diagnostic Codes 2 0 2c eee ee eee ne 94 Glossary Mn 97 Index o o oooo oo lt lt o MD 100 Notes MN 103 O 83 SPECIAL TORQUE CHART COMPONENT STANDARD A 44 Ibf in Camshaft follower retaining device bolt oocooooooo 10 Ibf ft Camshaft position CMP SeNSOF cceee eee eee nennen nn 96 Ibf in Camshaft thrust plate mounting bolts cece eee eee 23 Ibf ft Connecting rod De 33 Ibf ft a EE 50 Ibf ft le el See 30 Ibf ft Crankcase breather nuts under valve cover 65 62 Ibf in O aa 15 Ibf ft Crankshaft position CKP SenSor 0occoccccccccccocnnc nr 96 Ibf in Cylinder head bolts see figure A ooooccoccococcornnrnnnno figure A EGR cooler coolant supply port cover on oil filter base o A 89 Ibf in EGR cooler V band clamp ooo 53 Ibf
61. e ICP sensor is a three 3 wire variable capacitance sensor e The PCM supplies a 5 volt reference signal which the ICP sensor uses to produce a linear analog voltage that indicates pressure e The primary function of the ICP sensor is to provide a feedback signal to the PCM indicating ICP e The PCM monitors ICP as the engine is operating to modulate the IPR This is a closed loop function which means the PCM continuously 4115 monitors and adjusts for ideal ICP determined by conditions such as load speed and temperature e The PCM monitors the ICP signal to determine if the performance of the hydraulic system is satisfactory During engine operation if the PCM recognizes that the ICP signal is lower or higher than the value the IPR is trying to achieve the PCM will set a Diagnostic Trouble Code DTC and illuminate the amber malfunction indicator lamp on the dash e The ICP signal from the PCM is one of the signals the FICM uses to command the correct injection timing 61 ELECTRICAL COMPONENTS Mass Air Flow Sensor Powertrain Control Module Voltage Mass Air Flow Signal Analog Voltage 0 0 6 2 44 64 83 103 122 142 186 231 275 319 364 Flow Rate Grams Sec MAF Mass Air Flow e The Mass Air Flow MAF sensor uses a hot wire sensing element to measure the amount of air entering the engine Air passing over the hot wire causes it to cool This hot wire is maintained a
62. e The lube oil pump is located to the front cover by dowels and sealed with a push in place gasket O M Front Cover Sealant Application When installing the front cover the joint between the crankcase and main bearing carrier needs a dab of RTV sealer applied Note If too much sealant is applied it could get into the lube oil system O M Glow Plug Buss Bar Removal e In order to access the glow plugs the glow plug buss bar must be removed e To remove the glow plug buss bar pull out on the bar evenly e After the buss bar has been removed the glow plugs can be accessed through the rocker carrier e To reinstall the buss bar push evenly on the bar to seat the o rings on each connection e Note Do not hit the buss bar with a hammer damage may occur UNIQUE SERVICE PROCEDURES Crankshaft Rear Seal Dust Cover There is a metal plate pressed onto the primary flange of the crankshaft This plate acts as a dust shield for the rear seal and the mounting surface for the flexplate flywheel The plate must be removed before the rear cover can be removed It can be removed with a common finger type gear puller 78 Crankshaft Primary Flange The crankshaft primary flange is bolted to the rear of the crankshaft and it provides the sealing surface for the rear seal The flange is machined after being bolted to the crankshaft Note Do not remove the six bolts in the primary flange If the bolt
63. e bed plate to the front cover 9a e E O0 00 OQ Right Bank Lube Pressure Oil System Schematic DIESE OO OG T Tappet CB Cam Bearing MB Main Bearing CR Connecting Rod Piston Cooling J et WIDER OIL PAN O O OO AA AG Left Bank 37 LUBRICATION SYSTEM OIL PICK UP TUB Pick up Tube Oil Aeration The pick up tube supplies oil from the oil pan to the oil pump The pick up tube is sealed to the upper oil pan utilizing an o ring If the o ring is damaged or missing it could cause oil aeration and poor performance Oil aeration is the result of air being introduced to the lubrication system on the suction side of the system or by the breakdown of the anti foaming agents in the oil Oil aeration can cause low power and poor idle A damaged or loose pick up tube could also cause oil aeration Oil Pressure Regulator The oil pressure regulator is located in the front cover just below the gerotor oil pump The oil pressure regulator is calibrated to open at pressures above 75 psi It should be closed below that pressure A Gerotor Oil Pump The gerotor oil pump is driven off of the flats on the nose of the crankshaft The pump is designed to flow the large volume of oil required for the 6 0L POWER STROKE The gerotor oil pump front cover is located by two 2 dowel pins in the crankcase front cover and is sealed by a press in place gasket The outer housin
64. e pump to the left and back from injector operation right branches and to the IPR valve in the high pressure pump cover e Injectors deliver fuel when the spool l l valve is positioned to allow oil to e High pressure oil stand pipe enter the area above the intensifier connects to the branch outlets and piston provides a path through the pushrod area to the high pressure lines E 40 FUEL MANAGEMENT SYSTEM High Pressure Oil System Schematic CEA Oil Reservoir for Filter High Pressure u on Pump 0 95 Qt k 3 Ty UT y v b g Es 8 II OT U DO gt Cooler La B O 25 PSI High Pressure Pum P CT O Pump Bypass 70 PSI mi JN Sensor High Pressure Oil System Schematic After lube oil is cooled and filtered some is directed to the reservoir The reservoir provides oil to the high pressure pump The IPR Injection Pressure Regulator is PCM controlled and contains the system s pressure relief valve which opens at 4000 psi The plumbing from the pump to the high pressure oil rails for each head contains a check valve and orifice The oil rails are not cast into the head but are removable and z 4 O lt a lt Ay T Check Valve with Orific e d IPR Valve Contains Drain to Crankcase 4000 PSI Relief Valve fastened to the cylinder head and connected to the top of the injectors 86 41 FUEL MANAGEMENT SYSTEM High Pressure Pump 8
65. e removing the rocker arm carrier the glow plug and injector connectors must be removed from the carrier The rocker arm carrier is held in place with the cylinder head bolts There are also five 5 small bolts that hold the cylinder head in place Note If one or more of the cylinder head bolts are removed required for rocker arm carrier replacement then the cylinder head gasket and all cylinder head bolts must be replaced When reinstalling the carrier be sure to realign the rocker fulcrums as shown below Rocker Arms Bridges The rocker arms must be installed in their original position during reassembly e The valve bridges that connect the two 2 mating valves must be installed in their original position and orientation during reassembly Note If the rocker arms and or valve bridges are not correctly installed premature valve train wear may result Cylinder Head Rocker Fulcrums To remove the rocker arm fulcrums first remove the corresponding head bolt and then the small fulcrum retaining bolt Note If one or more of the cylinder head bolts are removed required for rocker arm carrier replacement then the cylinder head gasket and all cylinder head bolts must be replaced When reinstalling the fulcrums make sure the alignment dowel is in place and not damaged to insure that the fulcrum is properly aligned for correct valve train geometry First install the small fulcrum bolt then the head bolt an
66. egulated to 75 psi via the oil pressure regulator relieving excessive oil pressure to the inlet of the oil pump From the oil pump oil is directed to the oil ty cooler and then the to the oil filter elie From the oil filter the oil is supplied to four 4 passages One is to the turbocharger for lubrication and VGT control via an external line 8 U Y 3 sas Oil Reservoir The oil also is provided to the oil reservoir 25 PSI for High that supplies the high pressure oil pump Pressure PP INP p p Pump 0 95 Qt The two 2 other passages are to the tappet oil feed on the right and left banks The DEN tappet galleries also provide oil to the piston Pressure Oil cooling jets een Pop Cross drillings off of the right bank tappet gallery feed the cam bearings then the crankshaft main bearings The crankshaft has cross drillings in it to direct oil to each of connecting rod bearings 22 Oil Pan Bed Plate The 6 0L Power Stroke uses a two piece oil pan The lower half is wider than the bottom of the engine to increase its capacity Due to this wider oil pan an upper oil pan is used to adapt the lower pan to the bed plate The upper pan also acts as an oil baffle The upper pan is bolted to the bed plate The bed plate replaces the individual main bearing caps This one piece design results in a more rigid bearing retaining system The pick up tube is bolted to the upper pan and oil is routed through the upper pan and th
67. emove the injector connector from the rocker arm carrier use a twelve 12 point 19mm socket Place the open end of the socket over the connector and push inward lightly to disengage the locks and then pull the connector out of the rocker carrier Injector Removal cont e To remove the injector loosen the 140 torx socketed bolt that holds the injector in place this will also unseat the injector from it s bore e Note Do not use air tools to remove the injector e Carefully lift the injector from the bore e Note Do not pry on the injector coils to remove the injector they may be damaged and are not replaceable Also watch for rocker arm to injector interference e Note Make sure that the copper gasket at the bottom of the injector has not fallen into the injector bore Injector O ring Replacement e Once the injector has been removed carefully remove the external o rings e Note Be careful not to scratch the injector body during removal or the replacement o rings may not seal e Carefully install new o rings on the injector body e Note If the o ring is cut or nicked during assembly it will have to be replaced FUEL UPPER e Note Do not pull on the wires while working with the injector FUEL LOWER COMBUSTION GAS SEAL 136 70 UNIQUE SERVICE PROCEDURES gt N 4 MN AS INTERNAL UPPER O RING IS NOT REMOVABLE ft 9mm DEEP WELL SOCKET 137 FUEL INL
68. ers ECT Engine Coolant Temperature Sensor A thermistor style sensor used to indicate engine coolant temperature EGR Cooler A device used to cool exhaust gases before they are returned to the intake air system EGR Exhaust Gas Recirculation Valve A valve used to control the flow of exhaust gases into the intake manifold EGRP Exhaust Gas Recirculation Valve Position Sensor A potentiometer style sensor that indicates the amount of movement of the EGR valve EOP Engine Oil Pressure Sensor A variable capacitance style sensor used to indicate engine oil pressure EOT Engine Oil Temperature A thermistor type sensor which indicates engine temperature EVRT Control Valve See VGTCV Variable Geometry Turbocharger Control Valve EVRT see VGT Variable Geometry Turbocharger FICM Fuel Injection Control Module An electronic unit which has the primary function of an electronic distributor for the injectors It also is the power supply for the injectors 97 GLOSSARY Long Life Ethylene Glycol Coolant A premium coolant with an Ethylene Glycol base that can be used in a cooling system for an extended time without need ing to be changed Long life coolants do not require the use of extenders Long life coolants can be identified by its yellow color Glow Plug Sleeves Stainless steel sleeves used to protect the glow plugs from coolant GPCM Glow Plug Control Module Module which supplies power to the glow plugs and ident
69. fuel source Interferance on CKP amp CMP Faulty PCM of time Function of initial EOT in range fault based off of a change in EOT and MFDES P0197 C Engine Oil Temperature Sensor Circuit Low Input Checks EOT for a temperature higher than a specified oil Shorted to ground on the circuit temperature expected for normal operations WHEN eot P0196 Engine Oil Temperature Sensor Circuit Checks for an EOT temperature signal which is unable to Faulty Biased sensor circuit fault PCM Range Performance reach the EOT cold minimum limit within a specified amount VOLTAGE IS LESS THAN 0 15 VOLTS Default 212 F 100 C no fast idle P0198 C Engine Oil Temperature Sensor Circuit High Input Checks EOT for a temperature lower than a specified oil Open in circuit short to power temperature expected for normal operations when EOT voltage is greater than 4 76 volts Default 212 F 100 C no fast idle P0219 C Engine Overspeed Condition PCMrecorded excessive engine speed greater than 4300 Improper downshift Interferance on CKP amp CMP Faulty PCM rpm for more than 5 seconds P0230 C O R Fuel Pump Primary Circuit Fuel Pump Relay driver failure Open control circuit failed fuel pump relay or PCM P0231 Mak Fuel Pump Secondary Circuit Low No voltage present at the Fuel Pump monitor circuit when it Indicates open short circuit relay inertia switch or fuel pump has been commanded on for more than 1 second P0232 FRE Fuel Pump
70. g for the oil pump is designed into the crankcase front cover 23 LUBRICATION SYSTEM Front Cover e Oil flows from the crankcase to the oil pump via a passage in the back of the front cover e When the oil pump is turned by the crankshaft it creates oil pressure and pushes oil through one of two passages One passage is to the oil cooler and the other is through the oil pressure regulator back to the oil pump inlet e All of the passages from the front cover to the crankcase are sealed with a silicon in metal one piece gasket Sts Oil Cooler e The oil cooler is mounted in the valley of the engine and uses engine coolant to dissipate heat from the engine oil e Oil passes from the rear of the cooler to the front while coolant passes from the front of the cooler to the rear e The coolant and oil are separated by multiple plates that create passages in the oil cooler e Note If the oil cooler is damaged it could cause contamination of the lubrication and cooling systems Oil Cooler Housing amp Filter Base e The oil cooler housing has passages in it to direct the flow of coolant and oil e Oil is routed from the front of the crankcase to the back of the housing where it enters the oil cooler The oil passes from the rear of the oil cooler to the front of the cooler and is cooled in the process The oil is then sent to the oil filter through the oil filter base Filtered oil is sent to the oil reservoir for
71. ge continuously more than 23 3v Charging system fault 0478 P0565 C o IR Cruise Control ON Signal KOER switch test code set if cruise not present P0566 C Jo R Cruise Control OFF Signal KOER switch test code set if cruise not present er E Open hort t tch failure PCM fail failed t tivat P0567 JO Cruise Control RESUME Signal KOER switch test code set if cruise not present ld g a ek ee de le ne ne 5 a posee OJ Cruise Control SET Signal KOER switch test code set if cruise not present i Cruise Control COAST Signal KOER switch test code set if cruise not present A Brake Switch A Circuit Brake switch A circuit malfunction Cruise control code will be set on every switch test on vevicles not equipped with cruise control IR Powertrain Control Module Programming Error O O AAA AN Powertrain Control Module Keep Alive Memory KAM No historical faults output during self test Disconnected Discharged Battery Open PCM pin faulty PCM Error Powertrain Control Module Read Only Memory PCM failure Defective PCM ROM Error O 8 sill 5 c O R Starter Relay Circuit AA ooo 23 Ic O R Generator Lamp Control Circuit o SSS O 45 Ic oO R A C Clutch Relay Control Circuit o O 49 C JO R Cruise Control Lamp Control Cirouit EN IC O R Glow Plug Module Control Circuit Glow plug control module control line failure Open grounded circuit open shorted GPCM failed PCM 71 C O R Cylinder 1 Glow P
72. ge sizes through electronically con trolled hydraulics VGTCV Variable Geometry Turbocharger Control Valve Could also be called EVRTCV Controls oil flow in and out of the VGT actuator in order to change the effective size of its turbine housing VPWR Battery voltage VSS Vehicle Speed Sensor Normally a magnetic pickup style sensor that is mounted on the tailshaft of the transmission to indicate ground speed 99 INDEX A Actuators 64 Air filter filter minder 33 Air in fuel 79 Air management system features 31 flow 31 32 AP Accelerator Pedal 50 B BP Barometric Pressure 51 Barrel 44 bed plate 22 Bridges 72 C Charge air cooler 33 CKP Crankshaft Position 52 CMP Camshaft Position 53 Component Locations 9 13 Coolant recovery bottle 20 Cooling system Features 17 Flow 17 19 Crankcase pressure test 82 Crankcase ventilation 74 Crankshaft Heat treatment discoloration 15 Primary flange 78 Rear seal dust cover 78 Cylinder balance test 81 Cylinder head 14 Removal 72 100 D Dual mass flywheel 15 E ECT Engine Coolant Temperature 54 EGR Cooler 37 Installation 74 Removal 74 Flow 37 Throttle 38 Valve 37 38 Removal 73 VP Valve Position 55 Electrical Components 49 65 Emission label 8 Engine mounted fuel filter 30 Engine serial number 8 EOP Engine Oil Pressure 56 EOT Engine Oil Temperature 57 EP Exhaust P
73. has a fuel inlet check valve at the front of the head The check valve is incorporated into the bolt for the banjo fitting that attaches the fuel line to the head The check valves are used to maintain constant fuel pressure in the fuel rail The fuel lines are sealed to the head by two copper gaskets Note It is recommended that the copper gaskets be replaced if the bolt has been removed SECONDARY FUEL FILTER lt I E PF F a 7 2 02 3 ST PORT AIR MANAGEMENT SYSTEM Air Management System Features Air Management System e The air management system is made up of Com ponents Featu res the air filter turbocharger charge air cooler intake manifold and the EGR system e Air Filter Filter Minder e Variable Geometry Turbocharger VGT e Charge Air Cooler e Intake Manifold e EGR System Air management System Flow AIR MANAGEMENT SYSTEM Air Inlet Air Management System Intake Air _ Temperature gt IE Sensor 2 Manifold Absolute Pressure Sensor I System Flow e Air enters the system through the air filter where particles are removed from the air The air filter has a filter minder on it to warn the operator of a restricted air filter After the air is filtered the mass of the air and temperature is measured by the mass air flow sensor MAF e The filtered air is then directed past the crankcase ventilation system where crankcase vapors
74. he intake air temperature 2 IAT2 sensor are both mounted in the intake manifold e The passage at the rear of the manifold is to equalize pressure on both sides of the manifold SS te 38 THROTTLE PLATE INTAKE MANIFOLD EGRCOOLER FUEL MANAGEMENT SYSTEM Fuel Management System FICM PCM Fuel Injection Control Powertrain E CKP Module Control Module El M ve JO Lubrication System AP AL ai L o m EOT Eu BP u m EP High Pressure C CH Oil System r Be IAT 2 U U J gt amp GG OQ v E E E y EGR Fuel Supply u N Position System i m E mm mm E er I I Il c fm ICP Fuel Management System Major Components e Fuel Supply System e High Pressure Oil System e Lubrication System e Sensors e Injectors e Electrical Components e Actuators Fuel Management System Features e Emissions e Noise e Rate Control e Timing Control e No External High Pressure Lines e IPR valve with integrated pressure relief Generation ll Fuel Management System Diagram The generation Il fuel management system uses high pressure oil and electronics to actuate and control fuel injection in
75. he open position Once the desired turbocharger vane position is obtained the VGTCV goes to a neutral position and both the open and closed sides of the actuator piston is blocked off When the VGTCV is commanded to the full closed position high duty cycle oil from the oil supply line is directed through the actua tor piston to the closed side of the piston Oil on the open side of the piston is directed back to the VGTCV and then to drain 35 AIR MANAGEMENT SYSTEM VGT Turbine Vanes Closed ACTUATOR PISTON UNISON RING e During engine operation at low engine speeds and load little energy is available from the exhaust to generate boost In order to maximize the use of the energy that is available the vanes are closed In doing so the exhaust gas is accelerated between the vanes and across the turbine wheel In general this allows the turbocharger to behave as a smaller turbocharger than it actually is VANES Sa a 4 D e Closing the vanes also increases the back pressure in the exhaust manifold which is used to drive the exhaust gas through the EGR cooler and valve into the intake manifold This is also the position for cold ambient warm up S 73 VGT Turbine Vanes Partially Closed UNISON RING e During Engine operation at moderate engine speeds and load the vanes are commanded partially open VANES e The vanes are set to this intermediate posi tion to supply the correct amount of boo
76. here the gases are mixed with intake air to reduce NOx Nitrogen Oxide emissions and noise e The hot and expanding exhaust gases that are routed to the turbocharger turbine spin the turbine wheel through flow and expansion The spinning turbine wheel in turn spins the compressor wheel via a common shaft ME s 1 m gt lt o x y A gt _ N i A if A oa Y 4 Ta 7 w x Es Y 7 LN hO N y a Y LV N Mea i p y j i g w gt y nd hd a i Wi Air Filter Filter Minder The air filter is located on the drivers side of the engine compartment between the battery and the radiator e A filter minder device used to measure filter restriction is located on the back of the air filter housing e Fresh air from the drivers side fender and the grill area is drawn into the air filter and particulates are removed from the air before going to the engine Air Filter Element e The new air filter element is made into the air filter housing When replacing the filter the entire housing will have to be replaced e The air filter is capable of holding 1600 grams of particulates before needing replacement e The filter element is a honeycomb design Charge Air Cooler e The charge air cooler is located in the front of the radiator e It is an air to air cooler designed to lower the temperature of the air coming out of the turbocharger outlet
77. ifies variation in current flow to the glow plugs IAT Intake Air Temperature Sensor A thermistor style sensor used to indicate air temperature before the charge air cooler ICP Injection Control Pressure A variable capacitance style sensor used to indicate high pressure oil system pressure IAT2 Intake Air Temperature 2 Sensor A thermistor style sensor used to indicate air temperature after passing through the charge air cooler IDM Injector Driver Module An electronic unit which has the primary function of an electronic distributor for the injectors It also is the power supply for the injectors Impedance A form of opposition to AC current flow measured in Ohms I O Injector Test A test that can be performed using the WDS to disable one injector at a time while watching Mfdes to determine a weak contributing injector IPR Injection Pressure Regulator Controls injection oil pressure An electrical signal to a solenoid creates a magnetic field which applies a variable force on a poppet to control pressure The quantity of fuel delivered to the combustion chamber is proportional to injec tion control pressure IVS Idle Validation Switch An on off switch that indicates when the accelerator pedal is in the idle position KOEO Key on Engine Off Test A self test operation that is performed with the ignition switch in the ON position with the engine OFF KOER Key on Engine Running Test A self test operation that is performe
78. lug Circuit Glow plug 1 failure 2 Open shorted circuit faulty glow plug failed GPCM 72 C O R Cylinder 2 Glow Plug Circuit Glow plug 2 failure Open shorted circuit faulty glow plug failed GPCM 73 C O R Cylinder 3 Glow Plug Circuit_______________ Glowplug 3 failure___________________________ k Open shorted circuit faulty glow plug failed GPCM 74 C O R Cylinder 4 Glow Plug Circuit Glow plug 4 failure Open shorted circuit faulty glow plug failed GPCM 75 C O R Cylinder 5 Glow Plug Circuit_______________ Glowplug 5 failure Open shorrted circuit faulty glow plug failed GPCM 76 C O R Cylinder6 Glow Plug Circuit Glow plug 6 failure Open shorted circuit faulty glow plug failed GPCM 77 C O R Cylinder7 Glow Plug Circuit Glow plug 7 failure pen shorrted circuit faulty glow plug failed GPCM 1819 19 R Cylinder 8 Glow Plug Cireuit_ ____ Glow plug 8 failure _ __ Open shorted circuit faulty glow plug failed GPCM o e 00 C o1 39 C 48 C El so fe 79 C a PR Glow Plug Control Module to PCM Communication GPCM glow plug control module communication line failure Open shorted circuit failed GPCM failed PCM Circuit Glow Plug Control Module to PCM Communication Nosie was detected in the GPCM communication line Noise in GPD line Circuit Range Performance aaa A IR Transmission Control System MIL Request Brake Switch B Input Circuit KOER switch test Open short circuit switch
79. m 24 Nm 12 Nm 50 Nm 17 Nm 11 Nm 41 Nm figure A SPECIAL TORQUE CHART COMPONENT STANDARD METRIC Lower crankcase outer boltS oocooccccococcoco con 18 Ibf in 24 Nm Oil cooler mounting bolts MB c cece cece eee eee eee eens 16 Ibf ft 22 Nm MO lara daa 89 Ibf in 10 Nm Oil filter cap sasnsnnnnnnnonnnnnnnnenonnnnnnnnenennnnnnnnnnnnnnnnnnnnn nnn ee 18 Ibf ft 24 Nm Oil filter housing bolts cece eee eee nun nenn nenne nun nenn 11 Ibf ft 15 Nm Oil filter stand pipe bolt new urussnnnnnnnnnnnnnen nn nun nenn 53 Ibf in 6 Nm reinstallation cc ceeee eee ees 27 Ibf in 3 Nm Oil pan drain plug see note 3 cece cece cece e eee eee eee nn nn nn 18 Ibf ft 25 Nm Oil pickup tube flange bolts 0 e eee eee eee eens 18 Ibf ft 24 Nm Oil pump housing bolts _ uzeseunnnnnnnnnnnnnnnnnnnnnnnnnnnn nun 72 lbf in 8 Nm Oil pressure regulator PIUG c cece eee e eee cence eee eee eee eaes 19 21 Ibf ft 26 29 Nm Piston cooling jet see note 4 zzsunennnnnnnnnnnn nennen nenn 10 Ibf ft 13 Nm Rocker arm fulcrum bolts 0 ccc cece eee een eee een nn 23 Ibf ft 31 Nm Water pump bolts MB c cece cece eee eee eee ee een seen eeeeeeenes 17 Ibf ft 23 Nm Water pump PIUGS nnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 26 28 Ibf ft 35 38 Nm Water pump pulley DbDolts cee nn nn nn nn nennen 23 Ibf ft 31 Nm Thermostat housing bolts
80. n Turbocharged Diesel Engine 6 0L Power Stroke Overview e This publication is not intended to replace the Service Manual but to introduce the 6 0L Power Stroke engine Engine Features e The 6 0L Power Stroke has been designed to meet the customers expectations of high horsepower and torque over a wide RPM range e The 6 0L Power Stroke has also been designed to meet the tougher emissions standards set by the government e Meeting the more stringent customer and regulated demands are accomplished in part by VGT digital injection system 4 valves per cylinder and dual timing system Horsepower amp Torque e The 6 0L Power Stroke creates 325 horsepower at 3300 RPM and 560 ft lb of torque at 2000 RPM e Note Torque has increased and occurs at lower engine RPM than previous models Overview e Engine Features e Horsepower 8 Torque e Engine Specifications e Physical ID e Labeling Engine Features e Variable Geometry Turbocharger e Digital Fuel Injection e 4 Valves per Cylinder e Reusable Gaskets e Rear Gear train e Dual Timing System Horsepower Torque Chart engine speed rpm Torque ft lb Power bhp 6 0L POWER STROKE OVERVIEW 6 0L Power Stroke Diesel Specifications Engine Type Diesel 4 Cycle Configuration 4 OHV 1 Cam in Crankcase V8 Displacement 365 cu in 6 0 L Bore amp Stroken Grin ds 3 74 X 4 134 in 95 X 105 mm Compression Ratio Aspiration Rated Power
81. n what the injection control pressure ICP is Plunger amp Barrel e The bottom of plunger and barrel of the injector is where the fuel injection pressure is built e When the plunger is pushed downward by the intensifier piston it increases the fuel pressure in the barrel 7 1 times that of the ICP pressure e The plunger is coated with a tungsten carbide coating to reduce the possibility of scuffing and poor performance 44 Injection Nozzle The injection nozzle needle is an inwardly opening type which lifts off its seat when pressure overcomes the VOP Valve Opening Pressure of approximately 3100 psi Fuel is atomized at high pressure through the nozzle tip PINTLE D N Al N AP N A Kt ORL ie 27 AA TALILILIL 2 Ud dd ANZ u SEE EEE gt LI gt gt A See BN aN INN IN a SS so ATS INTENSIFIER PISTON 93 BARREL PLUNGER 94 95 FUEL MANAGEMENT SYSTEM e Fill e Main Injection e End of Main Injection RN N E AYA SPOOL VALVE I N x N CLOSED SA Da 2 AZ FUEL INLET IST 27 SS f Ni a PINTLE CLOSED OS PB SENT gt 24 7X dl INTENSIFIER PISTON AT REST Oil Pressure WMA High Pressure Oil EEE Atmosphereic Pressure Fuel Pressu
82. nal step Install remaining bolts and torque to 96 Ibf in 11 Nm in sequence shown above Intake Manifold Bolts e Step 1 Install bolts 1 through 8 finger tight e Step 2 Torque bolts 9 though 16 to 8 Ibf ft 11 Nm e Final step Torque all bolts to 8 Ibf ft 11 Nm in the numerical sequence shown Figure D 17 18 9 19 DO 7 15 16 m gt 5 a Q 2 e Q Figure E Main Bearing Bolts e Step 1 Torque the bolts to 110 Ibf ft 149 Nm in the numerical sequence shown e Step 2 Torque the bolts to 130 Ibf ft 176 Nm in the numerical sequence shown e Final step Torque the bolts to 170 Ibf ft 231 Nm in the numerical sequence shown 87 HARD START NO START DIAGNOSTICS TOMER NAME IF CONCERN IS FOUND SERVICE AS REQUIRED IF THIS CORRECTS THE MODEL YEAR VEHICLE SERIAL NO VIN CONDITION IT IS NOT NECESSARY TO F Series Excursion Powerstroke 2003 25 COMPLETE THE REMAINDER OF THE 6 0L Power Stroke Diesel Engine Diagnostic Guide DIAGNOSTIC PROCEDURE CHASSIS STYLE Customer Concerns Please list in this box DEALER NAME P amp A 1863 CLAIM NUMBER DATE CODE ENGINE SERIAL NUMBER ODOMETER TYPE OF SERVICE VEHICLE GVW TRANSMISSION AMBIENT TEMPERATURE PERSONAL C COMMERCIAL L Perform KOEO On Demand Self Test 11 Glow Plug System Operation NOTE A hard start No sta
83. nes Full Open Oil Supply Turbo Bearings VGT Control Valve Turbo Vanes Mid Position Return Oil 7 0 To Pan Oil Supply Turbo Bearings VGT Control Valve Turbo Vanes Full Closed Return Oil To Pan 7 4 Oil Supply gt 223222222220 0 5 gt o Ss x SOOO SOI OS Turbo Bearings Return Oil To Pan 7 2 The VGT control valve is commanded by the PCM based on engine speed and load The magnetic field generated by this signal moves a shaft in the control valve This movement meters engine oil through the valve to either side of the piston This design feature reacts quickly to changes in demand based on driving conditions When one side of the piston is pressurized the opposite side is vented Depending on which side of the piston is pressurized the vanes either open or close A cam follower at the end of the valve assembly provides feedback to the valve allowing it to reach a neutral position during times the vanes are not commanded to move AAN VGTCV Flows When the VGTCV is commanded to the full open position low or no duty cycle oil from the oil supply line is directed to the open side of the actuator piston Oil on the closed side of the piston is then directed through the actuator piston back to the VGTCV and then to drain Note If the VGTCV is disconnected the valve will default to t
84. nt cluster driver checks for Open Short circuit lamp fuse PCM open circuit or short circuit when lamp turns on and off Bed EGR Valve Position does not match desired limits based on EGR Valve stuck or sticking EGR Valve Position Sensor Bias EP engine speed load Sensor bias pl lr e EGR Valve Position does not match desired limits based on EGR Valve stuck or sticking EGR Valve Position Sensor Bias EP engine speed load Sensor bias with 1 Amp driver Internal to PCM Range Performance during normal driving conditions Pere A Fuel Level Indicator FLI Circuit Check Instrument cluster REFER to the appropriate section in the Workshop Manual driver checks for open circuit or short circuit PSI absolute BIER Minimum EP when the engine is running Pressure Faulty EP Sensor PCM or VGT difference of 10 kPa 1 5 PSI from desired voltage is less than 0 03 volts voltage is greater than 4 8 volts per zen EP is higher than EP desired by 260 kpa 37 7 PSI for Faulty EP sensor VGT control valve slow to respond Stuck VGT greater than 30 seconds valve faulty PCM P0480 C IR Fan 1 Control Circuit P0500 IC Vehicle Speed Sensor A Vehicle speed sensor malfunction Sensor circuit PSM PSOM low transmission fluid P0562 FRE System Voltage Low PCM voltage less than 7v cause of no start misfire Low Vbat loose connections resistance in circuit Vref engine concerns P0563 C O R System Voltage High PCM volta
85. ntake Air Temperature 2 The IAT2 sensor is a two 2 wire thermistor type sensor The IAT2 sensor changes resistance when exposed to different air temperature When temperature decreases the resistance of the thermistor increases This causes the signal voltage to increase When the temperature increases the resistance of the thermistor decreases This causes the signal voltage to decrease 114 The primary function of the IAT2 sensor is to provide a feedback signal to the PCM indicating manifold air temperature The PCM supplies a 5 volt reference signal which the IAT2 sensor uses to produce an analog voltage that indicates temperature The PCM monitors the IAT2 signal to determine if the temperature is satisfactory During engine operation if the PCM recognizes that the IAT2 signal is lower or higher than the expected value it will set a Diagnostic Trouble Code DTC and illuminate the amber malfunction indicator lamp on the dash 60 ELECTRICAL COMPONENTS Powertrain Control Module Injection Control Pressure Sensor FICM Fuel Injection Control Module Fuel Quantity Timing and Control ICP Malfunction Injection Control Pressure Indicator Lamp Analog Voltage 5 _ 4 5 o 3 S 2 0 Py O 652 1076 1500 1925 2350 2275 3200 3623 4045 4061 IPR Injection Control Pressure PSI Injection Pressure Regulator ICP Injection Control Pressure e Th
86. o oooooonoooooo MN 6 Specifications 0 6 0 eee eee e e Identification oooooooooooooooooooooooo o o 8 COMPONENT LOCATIONS 9 Features o oooocoonooo o a e a 14 COOLING SYSTEM 17 System Flow 00 00 ccc ooo errr 17 Water PUMP 0 0 ccc eee eee o e 19 LUBRICATION SYSTEM 21 System FIOW 0 0 eee eee gt 21 FUEL SUPPLY SYSTEM o CO 27 System FIOW 00 00 eee eee gt 2 Check Valve o ooooooocoooooonaoooa o e gt 30 AIR MANAGEMENT SYSTEM 31 System FlOW 00 00 cc eee eee eee gt 31 VGT oo e cc ee 34 EGR 1 ce 3 FUEL MANAGEMENT SYSTEM 39 High Pressure Oil System ooooooo momo nn nn MI 40 System FIOW o ooooccooooooooo eee eee eee gt 40 Fuel Injectors 0 0 cc eee a re 43 Stages of Injection 0 0 cc eee MI 45 ELECTRICAL COMPONENTS 49 Sensors 2 eee ere 49 Actuators 0 0 cece a 64 Other Electrical Components ooooo lt o lt MI 65 UNIQUE SERVICE PROCEDURES 69 GENERAL DIAGNOSTICS 19 APPENDIX O 83 This page intentionally left blank 6 0L Power Stroke Direct Injection Turbocharged Diesel Engine 6 0L POWER STROKE OVERVIEW 6 0L Power Stroke Direct Injectio
87. or e The injector coils are turned on for approximately 800 usec micro second or millionth of a second e No special tools are needed to remove the injectors from their bore The injector is slowly removed from its bore by removing the hold down clamp bolt Injector amp O rings The injector has two 2 replaceable o rings on the outside of the body one 1 internal non replaceable o ring in the top of the injector and one 1 replaceable copper combustion gasket on the tip of the injector The injector s two 2 coils have a single four 4 pin connector that passes through the rocker arm carrier _ Injector Coils amp Spool Valve e There is an open coil and a close coil on the injector that move the spool valve from side to side using magnetic force e The spool valve has two positions when the valve is in the open position it allows oil to flow from the high pressure oil rail into the injector When the valve is in the closed position it allows oil to drain from the injector back to the crankcase The total movement of the valve is only 017 43 FUEL MANAGEMENT SYSTEM Intensifier Piston e When the spool valve is in the open position high pressure oil is allowed to enter the injector and pushes the intensifier piston and plunger downward e Since the intensifier piston is 7 1 times greater in surface area than the plunger the injection force is also 7 1 times greater at the plunger tha
88. pe sensor e The PCM supplies a 5 volt reference signal which the EOT sensor uses to produce an analog voltage that indicates temperature e The PCM monitors engine oil temperature via the EOT sensor signal to control EGR glow plugs VGT and fuel quantity and timing throughout the operating range of the engine e The EOT signal allows the PCM to compensate for oil viscosity variations due to temperature Valve Valve Regulator changes in the operating environment ensuring adequate power and torque are available for all operating conditions FICM Fuel Injection Control Module Fuel Quantity Timing and Control Malfunction Indicator Lamp Glow Plug Lamp dm Glow Plu F Control Control Injection Pressure el Control MES LO 111 57 ELECTRICAL COMPONENTS Exhaust Pressure Sensor 2 2 D O O C O O to E D O a Ele 1 EP Exhaust Pressure Analog Voltage A 5 4 8 3 amp S 2 EA IT 0 HEB 0 15 25 37 46 54 EGR Exhaust Pressure PSI Control Valve EP Exhaust Pressure e The EP sensor is a three 3 wire variable capacitance sensor e The PCM supplies a 5 volt reference signal which the EP sensor uses to produce a linear analog voltage that indicates pressure e The EP measures exhaust back pressure so that the PCM can control the VGT and EGR system 98 FICM Fuel Injection Control and Control Malfunction
89. r EGR position sensor PID and calculate travel Spec Percent Actual Percent 0 0 6 1 2 V Closed 90 100 4 0 4 52 V Open 90 and 3 2 V Travel Repair issue causing out of spec values before continuing 9 Exhaust Restriction e Visually inspect exhaust system for damage Travel e Monitor EP with the scan tool with the engine temperature at 70 C 170 F minimum at 3 800 RPM in park neutral Parameter Spec Measurement MAX 3800 RPM 10a Electric Fuel Pump Pressure Measure fuel pressure at engine filter housing test port Road Test engine at full load condition Instrument Spec Measurement 0 1 1 Mpa 310 379 kPa 0 160 PSI 45 55 PSI min Gauge If fuel pressure fails low Go to step10b 10b Electric Fuel Pump Inlet Restriction e Measure restriction at fuel pump inlet Instrument Spec Measurement vacuum If gt 6 Hg restriction check lines between pump and fuel tank If lt 6 Hg inspect both fuel filters If filters are OK check fuel regulator If regulator and filters are OK replace fuel pump 10c Fuel Aeration Test e Install clear hose on fuel return line at fuel control module Refer to shop manual for approved procedure e Run at WOT for 2 min Return fuel should be free of bubbles visual If air is present in return fuel inspect fuel system for leaks 11 Perform KOER On Demand Test e This will test the ICP EGR and VGT performance K
90. rd the center of the engine e There is a port on the intake manifold for cooling system deaeration that returns to the coolant reservoir _ IPR Valve Removal To remove the IPR valve use the IPR socket tool 303 769 and turn counterclockwise e Note The connector for the IPR might hit the cylinder head If this occurs the coil body can be repositioned on the valve 75 UNIQUE SERVICE PROCEDURES High Pressure Pump Cover Removal e After removing the bolts that hold the high pressure pump cover to the crankcase pull the cover straight up to disengage it from the high pressure pump discharge tube e When reinstalling the cover be sure to lubricate the discharge tube o ring before installing the cover Front Cover Removal e The point were the crankcase and main bearing carrier meet is sealed to the front cover gasket with a dab of RTV sealant that must be cut to remove the front cover gasket SS lls Front Cover Dowel Locations e The front cover is located to the crankcase with dowels e Note If the dowels are missing or damaged the front cover could be misaligned and damage to the cover or oil pump could result 76 UNIQUE SERVICE PROCEDURES Front Cover Gerotor Oil Pump 4 t gt a E ar gt j a E r A a m EE NE 1 A 4 I UPPER PANEM LOWER PA BIT i par a i j f y L bi CONNECTOR O RINGS Ven e yy 4 r i
91. re BEE Fuel Supply Pressure NA Less Than 3100 PSI WWA Above 3100 PSI 97 Stages of Injection The injection cycle has three 3 stages Fill Main injection End of main injection During some conditions the injector will perform all three steps of the injection cycle two times per firing cycle This is called pilot injection O Fill Cycle During the fill stage the spool valve is in the closed position High pressure oil from the oil rail is dead headed at the spool valve Low pressure fuel fills the port below the plunger The needle control spring holds the needle on its seat so that fuel can not enter the combustion chamber 45 FUEL MANAGEMENT SYSTEM Main Injection Step 1 e Pulse width controlled current energizes the open coil magnetic force moves the spool valve to the open position e High pressure oil flows past the spool valve into the intensifier piston chamber e Oil pressure overcomes the intensifier piston spring force and the intensifier starts to move e Fuel inlet check ball seats due to an increase of fuel pressure under the plunger e Fuel pressure starts to build once the plunger passes the fuel spill port of the barrel e Force on the nozzle needle begins to build AA lt Main Injection Step 2 e The pulse width controlled current is shut off after 800 usec micro second or millionth of a second but the spool remains in the open position e High pressure oil f
92. ressure 58 F Features 6 FICM Fuel Injection Control Module 65 Forward 1 Front cover 24 Dowel locations 76 Installation 77 Removal 76 Fuel filter replacement 69 Fuel injector 43 Coil 47 End of main injection 47 Features 43 Fill cycle 45 Main injection 46 O rings 43 Spool valve 43 INDEX Fuel inlet check valves 30 Fuel pressure regulator 30 Fuel supply system Features 27 Flow 27 28 G Generation II fuel management system advantages 39 diagram 39 major components 39 Glow plug 67 buss bar 67 Removal 77 removal 77 sleeve 20 67 Removal 73 System 66 Diagnostics 68 CM Control Module 66 H HFCM Horizontal Fuel Conditioning Module 29 High boost 79 High EP 79 High pressure oil rail 42 High pressure oil system flow 40 41 High pressure pump 42 cover 42 removal 76 Horsepower amp Torque 6 IAT1 Intake Air Temperature 1 59 IAT2 Intake Air Temperature 2 60 ICP Injection Control Pressure 42 61 low 80 Injection nozzle 44 Injector Buzz 82 I O test 80 Installation 71 O ring replacement 70 71 Removal 69 70 Sleeve 19 Installation 73 Removal 73 Intake manifold 38 75 Intensifier Piston 44 IPR Injection Pressure Regulator 42 64 Valve removal 75 L Lubrication system Features 21 flow 21 22 M MAF Mass Air Flow 62 MAP Manifold Absolute Pressure 63 O Oil aeration 23 Test
93. rom the rail continues to flow past the spool valve e The intensifier piston and plunger continue to move and pressure increases in the barrel e When fuel pressure rises above the VOP Valve Opening Pressure of about 3100 psi the nozzle needle lifts off of it s seat and injection begins 46 T AN HHH N lala LTL I ae naj 7 ADA 2 nr N Se LR Ve Nas PINTLE CLOSED a A R HH N N N N Jooo oe 5 1 ll E 13 N Vu PINTLE OPEN ON DA nen a7 SPOOL VALVE OPEN INTENSIFIER PISTON MOVING DOWN Oil Pressure BEE High Pressure Oil EA Atmosphereic Pressure Fuel Pressure EEE Fuel Supply Pressure EEE Less Than 3100 PSI HE Above 3100 PSI 98 SPOOL VALVE OPEN INTENSIFIER PISTON MOVING DOWN Oil Pressure BEE High Pressure Oil EEE Atmosphereic Pressure Fuel Pressure BEE Fuel Supply Pressure BEE Less Than 3100 PSI BEE Above 3100 PSI 99 FUEL MANAGEMENT SYSTEM SPOOL VALVE en N N CLOSED ESTA NN Se QQ nn Za q A g N ES a da PINTLE OPEN a INTENSIFIER PISTON MOVING UP Oil Pressure BEE High Pressure Oil EEE Atmosphereic Pressure Fuel Pressure BEE Fuel Supply Pressure HA Less Than 3100 PSI BEE Above 3100 PSI
94. rt concern with EOT Temp below 60F perform step 10 first e Use scan tool DTC s set during this test are current faults GPCM Operation ct CY Glow Plug ON time is dependent on oil temperature Trouble Codes and altitude The Glow Plug Control Module GPCM Retrieve Continuous Trouble Codes comes on between 1 and 120 sec and does not come e Use the scan tool on at all if oil temp is above 131 F e DTC s retrieved during this test are historical faults e Using a scan tool check Continuous and KOEO DTC s Diagnostic If codes are present go to Pinpoint Test AF ie e Verify B voltage is being supplied to GPCM KOEO Injector Electrical Self Test Click Test e Using the scan tool GPCTM and EOT pids verify 1 Visual Engine Chassis Inspection Fuel Oil Coolant Electrical Hoses Leaks Method om OO Check Engine Oil Level e Check for contaminants fuel coolant e Use scan tool Injector DTC s will be displayed at test end glow plug on time All injectors will momentarily click then each injector will e Turn key to run position measure voltage on time e Correct Grade Viscosity e Miles Hours on oil correct level Method EEE Intake Exhaust Restriction e Inspect air filter and inlet ducts click in sequence 1 8 Sequence repeats three times Dependent on oil temperature and altitude Injector Relay on time Spec Measurement Trouble Codes 1 to 120 B
95. s are removed the crankshaft will have to be replaced or repeated seal damage will occur GENERAL DIAGNOSTICS Air in Fuel 4 b is ork a 7 El ede A e e zu TAN E e S ale Se re AR A A A A Air in the fuel supply system can cause rough run white smoke and low power To check for air in the fuel system remove the return line to tank from fuel pump module from the fuel pump module Install a 1 4 ID hose to the fuel pump module and place the other end of the hose into a diesel fuel safe container Turn the ignition to the on position The fuel pump will run for approx 20 sec Continue to cycle the key to the on position until fuel flows from the attached hose Start the engine run at WOT and observe the returning fuel for air If air is present the fuel will appear white foamy or non transparent If no or very little air is present in the fuel the fuel exiting the return hose will appear clear transparent Were to look a Fuel pick up in the fuel tank b Fuel supply line entering the fuel pump module from the fuel tank c Fuel return line entering the fuel pump module from the engine d Combustion leaks past the copper washer on the injector N High Boost High EP at WOT no Load If high boost consistently over 14 psi MGP and high exhaust pressure constantly over 23 psi EP is present at WOT no load the VGT or VGT control valve may be at fault To verify that
96. sing test by 12 way connector issue or logic power fuse port with a 0 160 PSI gauge at key on Refer to Pinpoint S for detailed 12 way conn diagnostics Fuel pump runs for 20 sec at key on and pressure C FICMVPWR No or low voltage indicated could be caused falls after key off by 12 way connector issues D RPM Low RPM can be caused by starting charging 0 160 PSI 45 PSI min system issues No RPM indicated while cranking could be Gauge CMP or CKP faults If pressure fails low go to next step to verify no restriction E ICP A minimum of 500 PSI 3 5 mPa is required for ia ai 6 Electric Fuel Pump Inlet Restriction the injectors to be enabled No or low oil in the system EOT F Measure restriction at fuel pump inlet system leakage injector O Rings faulty IPR or high Instrument Spec Measurement pressure pump could cause low pressure e Add 5 seconds to glow plug on time when above 0 30 Hg 6 Hg MAX IPR duty cycle defaults to 14 300 PSI w o CKP signal 7000 feet in altitude but not to exceed 120 seconds vacuum F ICP V Voltage reading below spec indicates low ICP If gt 6 Hg restriction check lines between pump and fuel tank during crank If lt 6 Hg inspect both fuel filters If filters are OK check fuel G FUEL PW Pulse width defaults to O w o CKP signal regulator If regulator and filters are OK replace fuel pump H FICMSYNC No sync could be caused CMP or CKP f
97. st to the engine for optimal combustion as well as providing the necessary back pressure to drive EGR e Note The VGT control valve piston is coupled to the vanes through a shaft and the unison ring SS Ll 4 ACTUATOR PISTON VGT Turbine Vanes Open e During engine operation at high engine speeds and load there is a great deal of energy available in the exhaust UNISON RING VANES e Excessive boost under high speed high load conditions can negatively affect component durability therefore the vanes are commanded open preventing turbocharger overspeed e Essentially this allows the turbocharger to act as a large turbocharger e 75 36 AIR MANAGEMENT SYSTEM INTAKE EGR Valve The PCM controlled EGR Exhaust Gas Recirculation valve adds cooled exhaust gases to the intake manifold to reduce NOx emissions The EGR valve is opened during steady state throttle positions when exhaust back pressures are higher than intake manifold pressures boost ON EGR Flow The EGR valve has two valves connected by a common shaft Cooled exhaust gases come to the center of the valve through a passage in the intake manifold When the valves open they allow exhaust gases to flow into the intake air stream from the top and bottom of the passage EGR Cooler The EGR cooler is a coolant to air heat exchanger that is used to cool the exhaust gases before they are sent to the EGR valve The exhaust gasses
98. stion chamber e The glow plug sleeve is replaceable See unique service procedures or the service manual for more details Coolant Recovery Bottle e The coolant recovery bottle is located above the left valve cover e One of the ports on the bottle is attached to the EGR cooler deaeration port If this port or hose is blocked damage could occur to the EGR cooler p _ t TW add ds i Atcha LUBRICATION SYSTEM e Integrated Oil Cooler e No External Oil Passages in Crankcase e Easy Access Canister Style Oil Filter e Front Oil Pressure Test Port e External Oil Pressure Regulator Lubrication System Features The 6 0L Power Stroke uses an oil cooler that is mounted in the valley of the engine under the oil filter There is also a oil pressure test port in the front of the oil cooler There are no oil passages located on the outside of the crankcase This reduces the chance for oil leaks The oil filter is a canister style filter mounted on the top of the engine that drains to the oil pan during servicing The gerotor oil pump and oil pressure regulator are both located in the front of the engine behind the vibration damper System Flow OIL FILTER BASE GEROTOR OIL PUMP OIL PRESSURE REGULATOR 36 21 LUBRICATION SYSTEM Lubrication System Oil Flow Oil is drawn from the oil pan through the pick up tube to the gerotor oil pump The oil pressure is r
99. t 200 C 392 F above ambient temperature as measured by a constant cold wire e The current required to maintain the temperature of the hot wire is proportional to the air mass flow e The MAF sensor then outputs and analog voltage signal to the PCM proportional to the air mass VPWR E COO IAT 1 MAF EGR Control Valve FICM Fuel Injection Control Module DOE ES t_ EVRT Control Valve 62 Fuel Quantity Timing and Control Malfunction Indicator Lamp m H gt IPR Injection Pressure Regulator 116 ELECTRICAL COMPONENTS Manifold Absolute Pressure Sensor FICM Fuel Injection Control Module Powertrain Control Module O O MAP gt EI A Fuel Quantity Timing and Control MAP Signal Analog Voltage 6 UL L 5 4 a o g 3 E D Malfuncti E 2 nn en ndicator Lamp 0 ED m 0 7 15 22 29 36 44 51 EGR VGT Manifold Pressure PSI Control Control Valve Valve MAP Manifold Absolute Pressure e The MAP sensor is a three 3 wire variable capacitance sensor e The PCM uses the MAP sensor signal to assist in the calculation of EGR duty cycle e The PCM measures the MAP signal to determine intake manifold boost pressure 63 ELECTRICAL COMPONENTS Actuators e Actuators convert electrical output from the PCM to hydraulic mechanical or electronic work The 6 0L Power Stroke uses four 4 act
100. t Cover e Coolant is drawn into the inlet of the front cover and then flows from the water pump through the front cover to the crankcase e Coolant is also routed from the front cover into the crankcase to a passage that feeds the oil cooler e Return coolant is directed to the thermostat by the front cover If the thermostat is open coolant flows to the radiator to be cooled If the thermostat is closed coolant is returned to the water pump via a bypass circuit in the front cover Cooling System Flow Back of Front Cover e Coolant is sealed via a silicon in metal one piece gasket and is directed out of the front cover through three 3 passages e Two of the passages route coolant to the crankcase to cool the cylinder walls and cylinder heads e The third passage routes coolant to the oil cooler via a passage in the crankcase e There are two passages for coolant to return from the crankcase into the front cover AA Cooling System Flow Oil Cooler e Coolant is directed out of the crankcase and into the oil filter base at the front of the engine e The oil filter base routes the coolant into the front of the oil cooler then toward the back of the engine e Once the coolant has passed through the oil cooler it is directed out of the oil filter base to the EGR cooler e Note There are weep holes in the oil filter base that allow coolant or oil to seep out side of the filter base if an oil cooler seal is damaged
101. the VGT is not being commanded to a closed position disconnect the wiring at the VGT control valve and run the engine at WOT If the readings do not return to normal then the VGT or VGT control valve are at fault 79 PR Ah mu N N AN E j A gu h h SN y y we N m y u A 2 b N A VA h q 4 A Y 4 a Y e al N a YE A A Xy pp a N A YY MM Y i V uw AY ww w UI ICP Pressure Low During Crank e If you have no 0 psi ICP pressure during crank it could be the result of major high pressure oil leak lack of oil supply to the high pressure pump bad high pressure pump or the gear on the high pressure pump is loose Use PC ED ICP diagnostics to determine root cause e If ICP during crank is between 200 300 psi and does not change as IPR duty cycle increases the IPR valve may not be receiving V power or a ground signal from the PCM If V power and PCM signal are present then the IPR may be at fault Use PC ED IPR Diagnostics to determine root cause Power or Ground Issues e When diagnosing a power or ground issue be aware that there is a 12 way connector that feeds power and or ground to the following components e FICM e IPR e EGR e The 12 way connector is located in the rear left hand corner of the engine compartment Injector I O Test e There is now a new test incorporated into the WDS e This test allows the techni
102. the turbocharger and to lubricate the bearings After oil passes through the turbocharger center section it is sent back to the crankcase via a turbo oil drain tube The turbo oil drain tube is located under the turbocharger and is sealed with two 2 O rings one fits into the turbocharger and the other goes to the high pressure oil pump cover FUEL SUPPLY SYSTEM Fuel Supply System Features e The fuel supply system uses a new Horizontal Fuel Conditioning Module e Horizontal Fuel Conditioning Module HFCM The HFCM filters fuel separates HFCM water senses water heats fuel and recirculates warm fuel through the pump e Secondary Fuel Filter during cool fuel conditions e Fuel Check Valves The 6 0L Power Stroke also has a secondary fuel filter e There is a check valve in the front of each cylinder head that does not allow fuel to return to the fuel supply system This type of system is called a dead end fuel system Engine Fuel System Flow FUEL FILTER FUEL SUPPLY FUEL SUPPLY TO HEADS FROM PUMP FUEL CHECK VALVES FUEL RETURN TO TANK 92 27 FUEL SUPPLY SYSTEM SECONDARY FILTER 4 MICRON AIR BLEED ELECTRIC TRANSFER Y amp PRIMING PUMP EZ X DD a ee gt ed FUEL DRAIN FUEL TANK PRIMARY FILTER WATER SEPARATOR 10 MICRON W HEATER 8 WIF PROBE Engine Fuel Flow e The fuel pump located in the Horizontal Fuel Conditioning Module H
103. to the cylinders O Generation ll Fuel Management System Major Components The fuel management system is comprised of several sub systems Fuel Supply System High Pressure Oil System Lubrication System Sensors Injectors Electrical Components Actuators O Generation Il Fuel Management System Advantages Emissions and noise have been reduced through improvements in rate and timing control No external high pressure oil lines exist The high pressure system s pressure relief is located in the IPR Injection Pressure Regulator 39 FUEL MANAGEMENT SYSTEM PUMP DISCHARGE LINE RESERVOIR HIGH PRESSURE CHECK VALVE STAND PIPE AND FITTING d j j Ji x 3 m i Y 4 j d d F P INJECTOR HIGH PRESSURE HIGH PRESSURE OIL RAIL PUMP GEAR HIGH PRESSURE PUMP HIGH PRESSURE RE OIL BRANCH AR OF ENG NE 85 High Pressure Oil System Flow High pressure oil line connects the l IN l stand pipes to the high pressure oil e Oil reservoir is filled by the lube oil rail system and contains approximately 1 qt e High pressure oil rail is bolted to the l l cylinder heads and acts as a e High pressure pump is sealed reservoir for high pressure oil inside the crankcase and has only one 1 outlet e Check valves incorporated in the l inlet fitting for the high pressure oil e High pressure pump discharge line rail limit hydraulic disturbance feed connects th
104. u Indicator Lamp 9 Glow Plug Lamp Q Control Module e The glow plug system is used to warm the air in the cylinders to enhance cold weather startability and reduce start up smoke PCM Powertrain Control Module p fe a a nna hin e The glow plug system is PCM controlled A 0 0 GPCM Glow Plug Control Module e The GPCM Glow Plug Control Module is a unit that controls the glow plugs in order to warm the air in the cylinders e The GPCM uses a glow plug enable signal to turn the glow plugs on for a time controlled by the PCM e The GPCM is capable of diagnosing a problem with one glow plug and then sending a diagnostic signal to the PCM e It also has the ability to turn off one glow plug if a short is detected in that circuit 66 ELECTRICAL COMPONENTS 127 128 Glow Plug e The glow plug is used to heat the air in the cylinder e Inside the plug are two 2 coils resistance connected in series one to create heat and one to control heat at its peak O Glow Plug Sleeve e The glow plug sleeve is used to protect the glow plug from engine coolant and is made of stainless steel A Glow Plug Buss Bar e Each bank of glow plugs is connected to the
105. uators Injection Pressure Regulator Exhaust Gas Recirculation Valve Variable Geometry Turbocharger Control Valve and Glow Plug Control module IPR Injection Pressure Regulator The IPR Injector Pressure Regulator is a duty cycle controlled valve that the PCM uses to control ICP Injection Control Pressure The IPR is a valve that blocks the path to drain for oil coming out from high pressure pump As duty cycle signal increases at the IPR the restriction to drain increases thus increasing ICP When the valve is disconnected it is in its open or drain state and the engine should not start The IPR valve also contains the pressure relief valve for the high pressure oil system 64 EGR Exhaust Gas Recirculation Valve The EGR Exhaust Gas Recirculation valve is used to mix cooled exhaust gasses with intake air to lower emissions and noise The EGR valve is duty cycle controlled the higher the duty cycle the more the valve opens When the valve is disconnected it is in its closed state e Injection Pressure Regulator IPR e Exhaust Gas Recirculation Valve EGR e Variable Geometry Turbocharger Control Valve VGTCV e Glow Plug Control Module GPCM O RINGS OIL IN OIL OUT COOLED EXHAUST INTAKE AIR K A O RINGS SS INTAKE AIR ELECTRICAL COMPONENTS VGTCV Variable Geometry Turbocharger Control Valve e The VGTCV Variable Geometry DRAIN TO PAN OIL SUPPLY
106. ults OOO MM Oil Aeration Test If oil aeration is suspected install a valve and hose into the oil system at either the EOT or EOP sensor Note All materials being used should be rated above 300 psi and 300 F Run the engine until the oil is at a normal operating temperature Run the engine at high idle for approximately one minute and then return to idle With engine at idle open the valve and drain a sample of oil into a clear container and observe for air or foam in the oil Caution Oil will be hot and under pressure OO C 81 GENERAL DIAGNOSTICS Crankcase Pressure Test e A new crankcase pressure orifice tool has been developed for the 6 0L Power Stroke e The new tool has a smaller orifice in the top so that more accurate readings could be taken with the 0 60 gauge on the gauge bar e When using the new tool on the 6 0L Power Stroke the maximum reading for a good engine is 8 of water A Lllt Injector Buzz No Buzz e Every time the key is cycled to the on position the injectors should buzz e If no buzz is heard one of the following conditions may be present a No power or ground to the FICM or PCM b No CAN communication between the FICM and the PCM c V ref shorted to ground d Bad PCM or FICM e All injectors bad or wiring to all injectors bad not likely e If the injectors do buzz and all conditions are met for the engine to run but the injectors do not fire

6.0L Technician Reference Manual

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