Ford 6.4L Power Stroke, Manual

Page 1: ...6 4L Power Stroke Diesel Engine 2008 F Series Super Duty Engine Description Systems Overview Component Location Technician Tips ...

Page 2: ...on a vehicle Always wear safety glasses for eye protection Always perform work in a well ventilated area Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Never perform any service to the engine with the air cleaner removed and the engine running unless a turbocharger...

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Page 4: ...ne Flow 21 System Flow 22 FUEL SUPPLY SYSTEM 28 System Flow 29 AIR MANAGEMENT SYSTEM 33 System Flow 34 Series Sequential Turbocharger 36 EGR 39 FUEL MANAGEMENT SYSTEM 41 System Flow 42 High Pressure Fuel Injection Pump Flow 43 Piezo Fuel Injectors 45 Stages of Injection 47 ELECTRICAL COMPONENTS 51 Sensors 52 Control Devices 68 Glow Plug Control Module GPCM 70 UNIQUE SERVICE PROCEDURES 73 APPENDIX ...

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Page 6: ... 6 4L Power Stroke Diesel Direct Injection Turbocharged Diesel Engine ...

Page 7: ...andards set by the government The 6 4L Power Stroke Diesel has been designed to meet the customers expectations of high horsepower and torque over a wide RPM range Meeting the more stringent customer and regulated demands are accomplished in part by High Pressure Common Rail Fuel System Series Sequential Turbocharger System 4 valves per cylinder and a dual timing system Engine Features High Pressu...

Page 8: ...m High Pressure Common Rail Direct Injection Total Engine Weight auto with oil 1130 lb 498 95 kg Coolant Flow to radiator 125 gal min 473 L min 3000 RPM Air Flow RPM compressor inlet 744 CFM 21 1 m3 min 3000 RPM Exhaust Flow RPM engine outlet 1962 CFM 55 6 m3 min 3000 RPM Oil Flow RPM 13 gal min 59 L min 3000 RPM Cooling System Capacity engine only 25 3 qts 24 L Lube System Capacity including filt...

Page 9: ...esignates Huntsville AL and U designates Indianapolis IN 0385535 is a sequential build number Serial Number Label Located on the top of the vertical EGR cooler States the engine serial number example at right 0385535 States the engine family example at right 6 4L DI turbo diesel Emissions Label States the horsepower rating for the engine programmed in the Engine Control Module ECM Depicts where th...

Page 10: ...GR Cooler Horizontal 2 EGR Cooler Vertical 3 Coolant Supply for Horizontal Cooler 4 Coolant Supply for Vertical Cooler 5 Turbocharger Outlet Front of Engine 1 ECT Sensor 2 Fuel Return Line 3 EGR Cooler Vertical 4 EGR Throttle 1 2 3 4 1 2 3 4 5 9 8 ...

Page 11: ...Housing Outlet 2 CMP Sensor 3 Oil Level Gauge 4 Fuel Supply Line 5 Fuel Return Line 6 EP Sensor 7 Glow Plug Harness 8 Heater Return Line 9 Degas Bottle Return Line Left Rear of Engine 1 EP Sensor 2 Turbocharger Crossover Tube 1 2 3 4 5 6 7 9 8 1 2 11 10 ...

Page 12: ...nt LOCATIONS Right Rear of Engine 1 Block Heater 2 EGRT Inlet Sensor Rear of Engine 1 Exhaust Expansion Joints 2 Catalyst 3 Lifting Eye 4 Serial Number 5 Turbocharger Outlet to Exhaust System 1 2 3 5 2 1 4 13 12 ...

Page 13: ...ht Side of Engine 1 CKP Sensor 2 Glow Plug Control Module 3 Crankcase Ventilation Oil Separator 4 Oil Seperator Drain Tube 5 Heater Supply Right Front of Engine 1 Injector Electrical Connector 2 Throttle Body 2 1 4 3 5 1 2 15 14 ...

Page 14: ...Fuel Return Cold outlet from cooler 8 LH High Pressure Fuel Line 9 EGR Valve 10 ECM Connection Top of Engine 1 High Pressure Turbocharger 2 Low Pressure Turbocharger 3 Turbocharger Oil Supply Line 4 EGR Valve Coolant Supply Port 5 EGR Valve Coolant Return Port Deaeration Port 6 EGRT Outlet Sensor 7 MAP Sensor 8 IAT 2 Sensor 1 2 3 5 4 6 1 2 3 4 5 6 7 8 7 8 17 16 9 10 ...

Page 15: ...4L Power Stroke Diesel engine uses larger head bolts than the 6 0L Power Stroke Diesel engine M16 vs M14 The 6 4L head bolts are also slightly shorter than the 6 0L head bolts The 6 4L head bolts do not retain the rocker carrier like the 6 0L head bolts do Intake Valves Exhaust Valves Injector Nozzle Glow Plug Fulcrum Plate Rocker Arms The fulcrum plate which holds the rocker arms is bolted to the...

Page 16: ... Geartrain The geartrain for the crankshaft camshaft and the high pressure fuel injection pump are located in the rear of the engine under the rear cover This allows for the high pressure fuel pump to be mounted inside the engine and also reduces noise The high pressure fuel injection pump turns at a ratio of 1 1 with crankshaft speed NOTE The helical cut gears used on the 6 4L differ from those u...

Page 17: ...nt pump can be serviced without disconnecting radiator hoses Both the glow plug sleeves and the injector sleeves are stainless steel Cooling System Features Coolant Pump Stainless Steel Injector Sleeves Stainless Steel Glow Plug Sleeves Internal Coolant Flow ...

Page 18: ...er receives coolant first then the coolant travels to the vertical EGR cooler through a short connection hose Hot coolant exits the vertical EGR cooler at the top and enters into the front cover A port next to the hot EGR return port in the front cover routes hot coolant to the heater core for vehicle heating The coolant then travels to a Y pipe where it meets with degas return coolant before bein...

Page 19: ...oolant Outlet to Crankcase Outlet from Cooler Oil Cooler Cover Top View Oil Cooler Cover Bottom View Oil Cooler Cover Oil Filter Base Oil Cooler Oil Cooler Coolant Flow Cooling System Flow Back of Front Cover Coolant is sealed via a metal one piece gasket and is directed out of the front cover through three 3 passages Two of the passages route coolant to the crankcase to cool the cylinder walls an...

Page 20: ...t arrives at the EGR valve Coolant Pump Front Cover The coolant pump hub and impeller is mounted into the front cover which is the housing for the water pump The coolant pump impeller pulls coolant from the center of the housing and pushes it outward The coolant pump has a built in reservoir to catch small amounts of coolant that during normal operation of the engine may seep past the seal This co...

Page 21: ...que service procedures or the service manual for more details Degas Bottle The degas bottle is located on the left side of the engine compartment and is part of the left side battery tray One of the ports on the bottle is attached to the EGR valve coolant line which is supplied from the top of the vertical EGR cooler If this port or hose is blocked damage could occur to the EGR coolers and or the ...

Page 22: ...esel uses an oil cooler that is mounted in the valley of the engine under the oil filter The oil filter is a cartridge style filter mounted on the top of the engine for ease of service This system also incorporates a valve that drains the oil to the pan when the filter is removed The gerotor oil pump and oil pressure regulator are both located in the front of the engine behind the vibration damper...

Page 23: ...oil back to the inlet side of the pump From the oil pump oil is directed to the oil cooler and then to the oil filter From the oil filter the oil is supplied to a chamber incorporating five 5 passages One 1 is to the turbochargers for lubrication Two 2 are to the EOT and EOP sensors The two 2 other passages are to the tappet oil supply on the right and left banks The tappet galleries also provide ...

Page 24: ...ssures above 65 psi It should be closed below that pressure The regulator valve utilizes a force provided via the regulator spring to apply a pressure equal to 65 psi Whenever oil pressure exceeds this force the regulator valve will move downward and allow the excess pressure to bleed off back through a passage that routes the oil back to the inlet side of the pump Gerotor Oil Pump The gerotor oil...

Page 25: ... the center where it is cleaned Note There is an oil filter bypass valve located at the top of the oil filter stand pipe plastic tube the oil filter slides over which will open and allow unfiltered oil to enter the system whenever a pressure differential of 27 psi is reached After being cleaned via the oil filter the oil is routed through the oil filter base and into a cavity that has ports to dir...

Page 26: ...the cooled filtered oil passage directly beneath them Oil Cooler Cover The oil cooler cover has passages in it to direct the flow of coolant and oil Oil is routed from the front of the crankcase to the rear 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 throu...

Page 27: ...assage to the inlet side of the pump thus regulating system pressure Oil Filter The 6 4L Power Stroke Diesel 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 The oil filter element snaps into the oil filter lid Note The oil filter lid should be remov...

Page 28: ... low pressure turbocharger drain extension tube is sealed via a rubber coated metal tube Oil Pan Bed Plate The 6 4L Power Stroke Diesel uses a two piece oil pan The lower half is wider than the bottom of the engine to increase the oil capacity of the system 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 ...

Page 29: ...arator Fuel Cooler 48 Fuel supply system 49 Fuel Supply System Features The fuel supply system uses a new Horizontal Fuel Conditioning Module HFCM The HFCM filters fuel separates water senses water and recirculates warm fuel through the pump during cool fuel conditions The 6 4L Power Stroke Diesel also uses 2 fuel filters and a stand alone fuel cooler system ...

Page 30: ... a return fuel line back to the HFCM The engine mounted fuel filter also contains air bleed orifices to remove air and return it to the tank After the fuel is filtered it is routed to the Internal Transfer Pump ITP The ITP is located inside the high pressure fuel injection pump and is used to increase the fuel pressure supplied to the high pressure fuel injection pump s three 3 internal pistons Af...

Page 31: ...e filter housing via a one way check valve 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 Fuel is then drawn through the 10 micron fuel filter and into the fuel pump Conditioned pressurized fuel is then supplied to the engine mounted fuel f...

Page 32: ...ilter 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 2psi 0 5psi Actual fuel pressure may be above or below this specification The regulated pressure of the valve is 3psi 0 5psi Actual fuel pressure may be above or below this specification NOTE The fuel pressure regulator is NOT serviceable separate from t...

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Page 34: ...perature of the pressurized air therefore inducing a cooler denser air charge into the intake manifold for maximum efficiency An air filter filter minder combination is utilzed to clean the incoming air and provide a means for monitoring the condition of the air filter via the filter minder The EGR system is designed to reduce exhaust emissions AIR Management System 58 57 Compressor Inlet from air...

Page 35: ...ed air via an air to air cooler then the condensed air passes through the EGR throttle mixes with cooled EGR gases then enters the intake manifold The intake manifold directs the cooled 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 and routes it to the high pressure turbocharger s turbine...

Page 36: ...ir filter and particulates are removed from the air before going to the engine Air Filter Element The new air filter element is a replaceable cartridge separate from the housing The air filter is capable of holding 750 grams of particulates before needing replacement The filter element is a honeycomb design Charge Air Cooler CAC The CAC is located in the front of the radiator The CAC is an air to ...

Page 37: ... before they enter the EGR system Turbocharger Actuator The variable vanes inside the high pressure turbocharger s turbine housing are now controlled by the turbocharger actuator The high pressure turbocharger s turbine housing contains vanes that control the effective size of the housing These vanes are controlled by the turbocharger actuator by way of a control arm The control arm connects the a...

Page 38: ...ssure turbocharger turbine housing after being directed through the exhaust up pipes at the rear of the engine The high pressure turbocharger turbine contains the vanes which are controlled by the turbocharger actuator These vanes continually change the velocity of the exhaust gas in the high pressure turbocharger turbine After the exhaust gas has passed through the high pressure turbocharger turb...

Page 39: ... up Vanes Partially Closed During Engine operation at moderate engine speeds and load the vanes are commanded partially open The vanes are set to this intermediate position to supply the correct amount of boost to the engine for optimal combustion as well as providing the necessary back pressure to drive EGR Note There is actually an infinite number of vane positions between open and closed The pa...

Page 40: ... of the EGR valve upper valve and the other is through a passage below the EGR valve lower valve Both passages merge together prior to being mixed with the filtered incoming air before being sent to the intake manifold Dual EGR Cooling System The EGR cooling system is an air to coolant heat exchanger that is used to cool the exhaust gases before they are sent to the EGR valve The exhaust is routed...

Page 41: ...old The intake manifold on the 6 4L Power Stroke Diesel is made of aluminum and directs the flow of air to the intake ports in the cylinder heads The manifold absolute pressure sensor MAP and the intake air temperature 2 sensor IAT2 are both mounted in the intake manifold Throttle Body Intake Manifold IAT 2 MAP Throttle Plate 73 ...

Page 42: ...ulations High Pressure Common Rail Fuel System Advantages Emissions and noise have been reduced through improvements in rate timing control and multiple injections The high pressure system s pressure relief function is now controlled by the PCV Pressure Control Valve which is mounted to the high pressure fuel injection pump The piezo fuel injectors help reduce noise while delivering optimum perfor...

Page 43: ...uel injection pump pressurizes the fuel it is routed to two 2 high pressure fuel rail supply tubes one for each bank HIGH PRESSURE FUEL SYSTEM The high pressure fuel rail supply tubes route the fuel to the high pressure fuel rail located under the valve cover The high pressure fuel rail inlet protrudes through the valve cover spacer at the back of the engine and oil is sealed by a rubber seal The ...

Page 44: ...ee 3 pistons 1 ITP internal transfer pump 2 VCV volume control valve 3 High Pressure Fuel Injection Pump Element 4 PCV pressure control valve 5 Inlet Pressure Control Valve 6 Lubrication Valve 7 Edge Filter a Fuel Inlet b High Pressure Connection c Fuel Return The pistons start their compression stroke via the offset journal and are returned to rest via spring pressure The pistons receive fuel fro...

Page 45: ...Valve The PCV and VCV are both installed in the high pressure fuel injection pump The PCV and VCV ARE NOT SERVICEABLE High Pressure Fuel Rail Fuel Rail Pressure Sensor FRP Fuel under extremely high pressures is delivered to the fuel injectors from the fuel rail by way of the fuel injector supply tubes The FRP sensor is located on the engine s right side high pressure fuel rail High Pressure Fuel I...

Page 46: ... of the injector The injector s piezo actuator has a single two 2 pin connector that is located under the valve cover The fuel charging harness has a single main connection point at the front of the valve cover spacer Piezo Actuator The piezo actuator is an electrically energized device that acts similar to a solenoid but is much more precise A piezo actuator is a composition of piezo discs that w...

Page 47: ...area for a downward force to overcome the pressure exerted by the smaller surface area of the nozzle needle in the high pressure chamber to keep the nozzle needle in a closed position Nozzle Needle The nozzle needle is an inwardly opening type which lifts off its seat every time the pressure in the high pressure chamber exceeds the pressure in the control piston chamber i e when the piezo is actua...

Page 48: ...er firing cycle Pre Main Injection The piezo electric fuel injector is constantly being filled with fuel via the high pressure fuel injection pump High pressure fuel from the high pressure fuel injection pump enters the following areas control piston chamber 2 spring side of the valve mushroom 4 high pressure chamber 3 The needle control spring 9 holds the needle on its seat so that fuel cannot en...

Page 49: ...eedle closed Main Injection Step 2 When the piezo actuator 1 is commanded on the actuator is energized which causes the piezo discs to deform and create a downward force and pushes the valve piston 8 downward The downward force of the valve piston pushes the valve mushroom 4 and spring down which opens up a bore hole that connects the high pressure fuel to the fuel return line 6 When this happens ...

Page 50: ... the polarity of the piezo actuator 1 which causes the piezo discs to return to a non enerrgized state Switching the polarity of the piezo actuator 1 enables the valve mushroom 4 to seat via spring pressure and completely block the bored passage that connects the high pressure fuel to the fuel return line Seating the valve mushroom 4 allows the pressure to build in the control piston chamber 2 and...

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Page 52: ...and the glow plug system Sensors Overview The ECM sends a reference voltage Vref of 5 0 volts external power to the pressure sensors and 5 0 volts internal power to the temperature sensors except for CMP and CKP which generate voltage through the collapse of a magnetic field The sensor signals are conditioned by the interface circuits within the ECM The signals are used as inputs to various contro...

Page 53: ...lues of the three potentiometers must agree During the movement of the AP if any 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 ECM will allow the engine to idle only and illuminate the check engine light Having three 3 signals for comparison is an added safety featur...

Page 54: ...ses to produce a linear analog voltage signal that indicates pressure The primary function of the Baro sensor is to provide altitude information so that the ECM can adjust timing fuel quantity glow plug on time and turbocharger control The Baro sensor is located inside the ECM If the sensor fails the ECM must be replaced ...

Page 55: ... for each tooth edge that breaks the magnetic field created by the permanent magnet that is in the end of the sensor Crankshaft speed is derived from the frequency of the CKP sensor signal Crankshaft position can be determined by the syncronization of the CMP peg signal to the CKP minus 2 slot signal Diagnostic information on the CKP input signal is obtained by performing accuracy checks on freque...

Page 56: ...trol Valve Crankshaft Position Sensor Throttle Body E Engine Chassis Turbocharger Actuator EGR Valve CMP Camshaft Position The camshaft position signal source is a magnetic pickup sensor mounted on the left front side of the engine block The sensor reacts to a peg pressed into the camshaft at the front of the engine The peg will pass the sensor once per camshaft revolution the sensor will produce ...

Page 57: ... divider with a pullup resistor inside the ECM 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 When the temperature of the coolant increases the resistance of the thermistor decreases and the signal voltage decreases ...

Page 58: ...es 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 ECM monitors EGRVP as the engine is operating to modulate the EGR valve This is a closed loop function which means that the ECM continuously monitors the EGRVP to ensure proper valve position ...

Page 59: ...ne 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 5 psi the gauge will show 0 The information from the switch is not sent back to the ECM in any way and is to be used as a reference only ...

Page 60: ... with a pullup resistor inside the ECM The ECM monitors engine oil temperature via the EOT sensor signal to aid in controlling fuel rail pressure FRP and fan control The EOT signal allows the ECM to compensate for oil viscosity variations due to temperature changes in the operating environment ensuring adequate power and torque are available for all operating conditions ...

Page 61: ...cated inside the Mass Air Flow MAF sensor The IAT1 sensor s internal thermistor forms a voltage divider with a pullup resistor inside the ECM The IAT1 sensor s primary function is to measure intake air temperature to aid in controlling EVTG and the glow plug system The MAF IAT1 sensor is mounted in the intake air piping after the air filter ...

Page 62: ...nce when exposed to different air temperature The primary function of the IAT2 sensor is to provide a feedback signal to the ECM indicating manifold air temperature The IAT2 sensor s internal thermistor forms a voltage divider with a pullup resistor inside the ECM The ECM monitors the IAT2 signal to control temperature by adjusting other devices ...

Page 63: ...ulate the PCV This is a closed loop function which means the ECM continuously monitors and adjusts for ideal FRP determined by conditions such as load speed and temperature The ECM monitors the FRP signal to determine if the performance of the fuel system is satisfactory During engine operation if the ECM recognizes that the FRP signal is lower or higher than the value the PCV is trying to achieve...

Page 64: ...e engine Air passing over the hot wire causes it to cool This hot wire is maintained at 200 C 392 F above ambient temperature as measured by a constant cold wire The current required to maintain the temperature of the hot wire is proportional to the mass air flow The MAF sensor then outputs a frequency signal to the ECM proportional to the air mass ...

Page 65: ...lculation of EGR duty cycle Fuel Delivery and Throttle Body Position The ECM measures the MAP signal to determine intake manifold boost pressure NOTE Washing a hot engine can have negative effects on this sensor NOTE The 6 0L engine used a remote mounted MAP sensor NOTE Pay special attention to differentiating between the MAP sensor and the EP sensor do not interchange them ...

Page 66: ...CM can control the EGR and the high pressure turbocharger via the turbocharger actuator NOTE Washing a hot engine can have negative effects on this sensor NOTE This sensor is gray in color for the 6 4L and black in color for the 6 0L Some early 6 4L engines may be equipped with black sensors Do not interchange 6 0L EP sensors with 6 4L EP sensors these sensors are different NOTE Pay special attent...

Page 67: ...e divider with a pullup resistor inside the ECM The FTS sensor changes resistance when exposed to different temperatures When the temperature of the fuel decreases the resistance of the thermistor increases and the signal voltage increases When the temperature of the fuel increases the resistance of the thermistor decreases and the signal voltage decreases ...

Page 68: ...ensor is a two 2 wire thermistor type sensor The EGRT outlet sensor s internal thermistor forms a voltage divider with a pullup resistor inside the ECM The ECM monitors exhaust temperature from the EGRT outlet sensor signal to aid in controlling the EGR valve position and throttle position ...

Page 69: ...is controlled by the ECM to maintain optimal fuel pressure throughout all engine operating conditions The PCV is permanently mounted to the high pressure pump and is not to be removed Removal of the PCV will result in replacement of the high pressure fuel injection pump NOTE Fuel caps have been left off for visualization purposes Always use fuel caps when servicing the high pressure fuel system VC...

Page 70: ... Actuator The turbocharger actuator is an electronic motor that controls the position of the vanes inside of the high pressure turbocharger s turbine housing The turbocharger actuator is mounted directly to the high pressure turbo and is connected to the vanes inside the turbine housing by a control arm Throttle Body The throttle body is operated by a stepper motor controlled by the ECM and assist...

Page 71: ...le GPCM Glow Plug Harness The GPCM is a unit that controls the glow plugs in order to warm the air in the cylinders The GPCM uses a glow plug enable signal to turn the glow plugs on for a time controlled by the ECM The GPCM is capable of diagnosing a problem with one glow plug and then sending a diagnostic signal to the ECM It also has the ability to turn off one glow plug if a short is detected i...

Page 72: ... to the glow plug used on the 6 0L Power Stroke Diesel but they are different The glow plugs must not be interchanged NOTE The 6 4L glow plug uses a green isolator Fuel Injector The fuel injector is controlled by an extremely precise piezo electric actuator that can accomplish multiple injections per combustion event NOTE Never unplug a fuel injector while the engine is running serious engine dama...

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Page 74: ...y Make sure your hands and any tools involved are clean also Remove the fuel filter lid and lift the filter element out of the housing and discard in the appropriate location To avoid fuel spills use a suction gun or similar device to remove the remaining fuel from the fuel filter housing Install the new filter and tighten the fuel filter lid to the specified torque NOTE Before starting the vehicl...

Page 75: ...iness practices while servicing the fuel system NOTE Follow the proper service procedures while servicing the fuel system and always use the correct torque Proper torque is crucial with the 6 4L Power Stroke Diesel s high pressure fuel system When replacing high pressure fuel tubes always follow the correct procedure for installation and torque Fuel System Service Cleanliness High Pressure Fuel In...

Page 76: ...ector Lubrication NOTE Use proper cleanliness practices while servicing the fuel system Always replace the O ring and the steel gasket at the tip of the injector when reinstalling an injector New injectors come with these items already installed Always lightly lubricate the new O ring with clean engine oil prior to assembly Fuel System Service Removing and Installing Injector Gasket NOTE Use prope...

Page 77: ...ngine Proper fuel pressure is very important Too much or too little pressure could be detrimental Follow the proper procedure for checking fuel pressure and make sure the correct specification for supply pressure is achieved NOTE Supply pressure needs to be checked at the horizontal fuel conditioning module HFCM outlet Test Port return pressure Turbocharger Assembly Tool The series sequential turb...

Page 78: ...ve or damage can occur to the EGR valve and or tool Crossover Tube Seal Removal Crossover tube seal removal requires the use of special service tools slide hammer seal removal tools There is a different size removal tool for each opening of the crossover tube Tool 303 1264 Crossover Tube Seal Installation When installing new seals into the turbocharger crossover tube always use the appropriate ins...

Page 79: ...the gear on the high pressure fuel injection pump with the gear backwards The gear and shaft both have a taper that needs to match If you tighten the gear with it backwards the tapers will not be aligned but the bolt will start providing a means of tightening Please pay special attention to insure that the gear is installed correctly with the tapers on both the gear and the high pressure fuel inje...

Page 80: ...each measurement point refer to the service procedure graphic in the Ford workshop manual with the straight edge perpendicular to the longitudinal and not across the area that contains the smaller head bolt holes Set the straight edge on top of the feeler gauge Use a firm steady force to properly hold the straight edge on top of the feeler gauge Pull lightly on the feeler guage The head is locally...

Page 81: ...proper order The coolers must first be installed loosely in the order shown then torqued in the proper sequence as shown in the Ford workshop manual Proper assembly is crucial due to the extreme temperature changes within the EGR coolers Temperature changes of 800 deg F are possible NOTE All bolts nuts clamps and cooler brackets must be replaced if the coolers are removed 1st 2nd 3rd 1st 2nd Intak...

Page 82: ...81 6 4l dit appendix TABLE OF CONTENTS Torque Charts 82 87 Wiring Diagram 88 89 Diagnostic Codes 90 101 ...

Page 83: ...Nm EGR throttle body to EGR valve housing 88 lbf in 10 Nm EGR valve housing to intake manifold 88 lbf in 10 Nm EGR valve to EGR valve housing 88 lbf in 10 Nm Engine coolant temperature sensor ECT 159 lbf in 18 Nm Engine oil pressure switch EOP 124 lbf in 14 Nm Engine oil temperature sensor EOT 159 lbf in 18 Nm Exhaust backpressure EP connector to DOC tube 20 lbf ft 27 Nm Exhaust backpressure EP tu...

Page 84: ...cooler to crankcase mounting bolts M8 23 lbf ft 31 Nm Oil filter base to cooler cover screws M6 thread forming 89 lbf in 10 Nm Oil filter cap 18 lbf ft 25 Nm Oil filter housing to filter base bolts 16 lbf ft 22 Nm Oil filter stand pipe bolt M5 thread forming W new oil cooler 61 lbf in 7 Nm Oil filter stand pipe bolt M5 thread forming reusing existing oil cooler 30 lbf in 3 Nm Oil pan bolt lower pa...

Page 85: ...Head Bolts Step 1 Lightly lubricate M16 head bolt threads and washer faces with clean engine oil prior to assembly Step 2 Torque M16 head bolts labeled 1 10 to 70 lb ft 95 Nm in numerrical sequence shown Step 3 Back out M16 head bolts and retorque to 115 lb ft 156 Nm one at a time in numerical sequence shown Step 4 Tighten M16 head bolts and additional 90 degrees in numerical sequence shown Step 5...

Page 86: ...bolts FIGURE E Vibration Damper Bolts Step 1 Torque each bolt to 50 lb ft 68 Nm in the numerical sequence shown Step 2 Tighten each bolt 90 degrees clockwise in the numerical sequence shown Note Damper bolts may not be reused once torqued FIGURE F Exhaust Manifold Bolts Step 1 Torque bolts to 18 lb ft 25Nm in the numerical sequence shown Step 2 Repeat the sequence using the same torque Note Exhaus...

Page 87: ...l side tube nuts to 106 lb in 12 Nm 2 0 Special torque sequence is used see note below Step 10 Place a visible mark with a permanent marker on the tube nut and the fuel injector threaded connection Turn the tube nuts one flat of the nut which is equal to 60 degrees Special torque sequence is used see note below Step 11 Place a visible mark with a permanent marker on the tube nut and the high press...

Page 88: ...un down and torque inboard upper bolt to 45 lb ft 62 Nm Step 6 Fully run down and torque outboard lower bolt to 45 lb ft 62 Nm Step 7 Rotate crankshafft 360 degrees to position it at the alternate cylinder TDC dowel pin at 10 30 position Step 8 Identify remaining group of fulcrum plates per step 3 and torque per steps 4 6 FIGURE K EGR Cooler Mounting Clamps Horizontal Cooler Step 1 Pre torque EGR ...

Page 89: ...88 wiring diagram single alt reference only Refer to Ford Wiring Diagrams for Wiring ...

Page 90: ...89 wiring diagram single alt reference only Refer to Ford Wiring Diagrams for Wiring ...

Page 91: ...ff time 5 0s 300 hPa 5 0 sec Wiring EP tube plugged EP Sensor MAP sensor PCM P008C X Fuel Cooler Pump Control Circuit Open This diagnostic will detect if the relay for the fuel cooling pump has an open load error P008D X Fuel Cooler Pump Control Circuit Low This diagnostic will detect if the relay for the fuel cooling pump has grounded P008E X Fuel Cooler Pump Control Circuit High This diagnostic ...

Page 92: ...mum intake manifold pressure indicating an open circuit or a short to ground This error occurs when the MAP signal voltage is lower than a specified value for a predetermined period of time 0 15v 5sec Wiring MAP sensor PCM P0108 X Manifold Absolute Pressure BARO Sensor High Input This diagnostic checks for a maximum possible intake manifold pressure indicating a short to power This error sets when...

Page 93: ... when the absolute fuel mass deviation of the available fuel mass estimate to the current set point falls outside of the fuel pressure dependent calibration threshold P02CE X X Cylinder 2 Minimum Fuel Mass Adaptive Learning at Min Limit This error occurs when the fuel mass estimated by the adaptation feature falls outside of a calibration threshold Injector P02CF X X Cylinder 2 Minimum Fuel Mass A...

Page 94: ...peed exceeds governed engine speed for a predetermined amount of time 4000 rpm P0231 X Fuel Pump Secondary Circuit Low P0232 X Fuel Pump Secondary Circuit High P0234 X Turbocharger Supercharger Overboost Condition This error occurs when the MAP sensor reading is above the threshold for a predetermined period of time 4050hPa 5 sec System error causes of overboost P0263 X X Cylinder 1 Contribution B...

Page 95: ...e at key on 1 sec Wiring CMP sensor PCM P0381 X Glow Plug Heater Indicator Circuit The instrument cluster performs the diagnostic of the wait to start indicator once per driving cycle and transmits the result to the PCM The PCM analyzes the message to check if the glow plug lamp circuit is operational P040B X X X Exhaust Gas Recirculation Temperature Sensor A Circuit Range Performance This error o...

Page 96: ...value is lower than a minimum probable temperature for a predetermined amount of time indicating an open circuit or short to power 0 15v 5sec Wiring Tegr_OUT sensor PCM P041D X X X Exhaust Gas Recirculation Temperature Sensor B Circuit High This error occurs when the EGR cooler outlet sensor temperature output value is higher than a maximum probable temperature for a predetermined period of time i...

Page 97: ...gnal This error occurs when the cruise control set switch is not depressed during the KOER self test or is stuck during continuous operation P0569 X X Cruise Control COAST Signal This error occurs when the cruise control coast switch is not depressed during the KOER self test or is stuck during continuous operation P0571 X Brake Switch A Circuit This error occurs when the brake switch is not depre...

Page 98: ... X X Sensor Reference Voltage A Circuit High This error occurs when the sensor reference voltage falls above a maximum threshold High 5 25 V Wiring PCM P065B X Generator Control Circuit Range Performance P0652 X X X Sensor Reference Voltage B Circuit Low This error occurs when the sensor reference voltage falls below a minimum threshold Low 4 75V Wiring to sensors PCM P0653 X X X Sensor Reference ...

Page 99: ... rpm based on a table 30sec Wiring MAF assembly PCM P1103 X Mass Air Flow Sensor In Range But Higher Than Expected This error occurs when the measured value of mass air flow is higher than a threshold value for a predetermined period of time 0 EGR Position 50 Engine speed 700 rpm 2400 rpm based on a table 30sec Wiring MAF assembly PCM P115A X Low Fuel Level Forced Limited Power This error occurs w...

Page 100: ...p sensor P1556 X X Injector Circuit Range Performance Cylinder 6 This error occurs when the minimum current rise time is outside the valid range max 210 V min 62 V Wiring to injectors injectors HP system coolant temp sensor P1557 X X Injector Circuit Range Performance Cylinder 7 This error occurs when the minimum current rise time is outside the valid range max 210 V min 62 V Wiring to injectors i...

Page 101: ...e Circuit Low Input This error occurs when the voltage signal from the barometric pressure circuit falls below a minimum threshold Low 2 22 V PCM P2229 X Barometric Pressure Circuit High Input This error occurs when the voltage signal from the barometric pressure circuit rises above a maximum threshold High 4 36 V PCM P2230 X Barometric Pressure Circuit Intermittent PCM P2262 X Turbocharger Superc...

Page 102: ...d is detected in the diesel particulate filter differential pressure sensor circuit P2455 X Diesel Particulate Filter Differential Pressure Sensor Circuit High This error occurs if a short to power occurs in the diesel particulate filter differential pressure sensor circuit P2456 X Diesel Particulate Filter Differential Pressure Sensor Circuit Intermittent Erratic This error occurs if the signal f...

Page 103: ...6 4L Power Stroke Diesel Engine Printed in U S A FCS 14853 MISC 2007 International Truck and Engine Corporation ...