Ford 7.3 DIT Power Stroke, Service Manual

Page 1: ... F Series Super Dutv Features Description 8ervice ...

Page 2: ...d 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 Be sure that the ignition switch is always in the OFF position unless otherwise required by the procedure Never perform any seNice to the engine with the air cleaner removed and the engine running unless a turbocharger compressor inlet shield...

Page 3: ...7 3L DIY Direct Injection Turbocharged Diesel Engine ...

Page 4: ...omparison 5 PHYSICAL ID 6 AIR CHARGING SYSTEM 13 Turbo ld 13 Wastegate Control 15 TURBO REMOVAL AND INSTALLATION 18 FUEL CHARGING SYSTEM 21 Injectors 21 Fuel Filter and Supply 24 High Pressure Oil System 29 NEW AND REVISED SENSORS 31 SPECIAL TOROUE DATA 33 7 3L DIT ANTHOLOGY 35 Fuel filter service 35 DIAGNOSTIC GUIDES AND FORMS 50 GLOSSARY 71 INDEX 73 1 ...

Page 5: ...otherwise stated fn text 4 F Series lacraaaad Harsapawer and Torque Charga Air Caalad llactranh ally Controlled Wastegated Turbo All Split Shot Injectors laap ta Connect ICP Oil Lines Jla aignad Fual Systam Econoline Snap ta Cannact ICP Oil Linas Radaaigaad Fual Supply Systam All Split hat lnjactors Carryover from 1817 Modal Yaar Chassis Power Train Changes Cha ia Mauntad Electric Fuel Pump ZF I S...

Page 6: ...0 350 300 3500 Eminion L t The emission label Is localed on lhe right valve cover and Identifies lhe engine model gross horsepower and fuel delivery rate Harupowar Comparlaon 1999 r Sarlo Peak Horsepower is 9 more than previous models and occurs 0 2700 RPM versus 3000 RPM Tar Ca parlua Similar to the horsepower 1ncrease peak torque is higher at 500 lb 11 between 1600 and 2300 RPM This Is a 15 1ncr...

Page 7: ...n of the crankcase has been modified to allow larger crankshaft counterweights to clear the crankcase The serial number break for this change is 571930 This change occurred on the crankcase prior to the crankshaft Note This crankcase may be used with either crankshafts described above Ca shaft The 1999 model year engine incorporates a chassis mounted electric luel pump Due to the use of an electri...

Page 8: ...ng muat not be used on earlier pistons Pistan The new piston has a deeper intermediate ring groove to accommodate the new increased intermediate ring width Note Pistons and rings cannot be Intermixed due to Increased and narrow intermediate ring widths Valwa Caver askat UVC Harn To reduce the number of electrical connections and improve reliability the valve cover gasket now uses a single 9 pin co...

Page 9: ... injector circuits The four White pins are for glow plugs The Black pin is common for the four Injectors Red Green Blue and Yellow pins are injector ground Exhauet Up Pipn To improve joint serviceability the exhaust up pipes are now common for both E and P Series On previous engines the exhaust up pipes were model specific The previous P series drivers side exhaust up pipe is shown 8 Essential too...

Page 10: ...sensor you will have to make your own cooling coils The coils are to coot exhaust gases before they reach the pressure gauge 10 avoid damage 10 lhe gauge The coil should be made oul of copper tubing oblained locally Aller making coil attach tubing 10 the exhaust manifold by removing he plug in front of the right exhaust manifold where the exhaust back pressure sensor tube would normally be located...

Page 11: ...ke it eas er to change or add 011 to the engine The dipstick is now common for both E and p series This makes It easier to check the oil level on P series Cnnkc Prauura Tnt Place crankcase pressure adapter on oil fill extension to check pressure Crankcase pressure shOuld not be more than 4 Inches of water usong the Magnahetic gauge Note Be sure to block oH crankcase ventilation system breather tub...

Page 12: ... to accumulate and evaporate This eliminates the staining seen on prior water pumps Thermostat Housing To provide clearance for charge air cooler piping and improve serviceability during normal service operations the p Series thermostat housing is shorter has a thicker H ange and a new seal Water Pump Pulley The water pump pulley diameter has been decreased If service is required be sure to use th...

Page 13: ...te a litter minder restnclion gauge to mon tor air filter cond ion Sinal Man Flywh J A single mass flywheel replaces the previously utilized dual mass flywheel for manual transmission appiiCabons The flywheel can be identified by the absence or bolts that would normally connect the inertia member from the clutch surtace Note The single mass flywheel can only be used with the ZF 6 speed manual 12 P...

Page 14: ...w shown the EBP regulator and new top down turbo to pedestal mounting bolts are depicted The wastegate regulates maximum speed of the turbocharger by allowing excess exhaust gases to bypass the turbine housing and be directed into the exhaust stream to atmosphere Turha r Sari with Wastagate and EBP From the rear view EBP and wastegate actuators are shown In addition note the locator dowel hole for...

Page 15: ...own utilizes an alignment dowel for positioning on the IU11line housing Turbo E Sarles without Waala1ala and with EBP Front view shown with EBP regulator moved to front of pedestal and top down mounting bolts Becausa the e Series does not utilize charge cooling wastegaled turbochargers are not incorporated in the Econollne engines 1 4 Thrbo mounting bolt No EBPregulator No EBPactuator Thrbo mounti...

Page 16: ...inlst CAC Houai l a11d w c Note The Inside of this housing will be damp with oil mist carry over from the closed crankcase ventilation system Oil is not an indicator of a turbocharger concem w c s Linea With the electronically controned wastegate a pressure drlferenlial between the induction system and the intake is used to regulate boost pressure via a duly cyCle controlled PCM solenoid 15 ...

Page 17: ...age Waotogala Aclualar Dlagnaallu To test the wastegate actuator apply regulated air pressure to the actuator starting at zero 11nd slowly increasing pressure while observing actuator rod movement The actuator should start to move at 5 psi The actuator should hold 5 psi lor 30seconds lnlaka Ia CAC Hauslna Hu The CAC intake air hOse has offset diameter tnlet and outlet this is due to the diHerence ...

Page 18: ...ent and no wheel to housing contact is present the sound may be normal Door hinges Sound insulating material shown from inside the lender Sound insulating material shown from inside the vehicle Sound insulating material shown out of vehicle side view Sound Insulating Material far Engina Naisa When diagnosing engine noise complaints such as turbo whine you must first check to see that all sound ins...

Page 19: ...ance and Internal engine protection CAC Cenn llens Note Alter removing the charge air pipes It Is normal to aee oil inside the flexible hose area CAUTION When the intake system is open care must be used to avoid any foreign objects from entering the engine or charge air cooler system CAC C nn ll ns Next loosen the two clamps on both lower charge air cooler pipe connections at the charge air cooler...

Page 20: ...ding charge air cooler housing to turbo and Intake covers Air lnduclian Hue Loosen the two ctamps hold ng the air intal e hose to the turbo Remove the air intake hose Exltau t Pipe Next lOosen v band ctamp holding exhaust pipe to turbo Move exhaust pipe out ot the tor turbo removal When reinstalling ctamp tighten to 50 tbtlin 5 6 Nm 19 ...

Page 21: ... reinstalling clamp tighten to 100 lbliln 11 3 Nm Tarloachar1ar AuamlolJ Note In chassis removal and installation of turbo requires leaving the pedestal attached to the engine Remove the two bohs hokling the turbo to the mounting pedestal When reinstalling bolts tighten to 35 lbs 11 4 Nm To install turbo reverse above steps 20 ...

Page 22: ...e unseats the delivery check ball and begins fuel delivery Split Shat Dpuatlaa Split shot Injectors provide improved exhaust emissions and quieter engine operation particularly at Idle by talloring the injection of fuel without a decrease In performance Split shot infectOrs prime have been used in Calllom1a engines since the 1996 model year and all 1997 Econohnes Now they are 10 all Power Strokes ...

Page 23: ...upper port in the barrel pressure decreases and fuel delivery is stowed When the upper land seals the upper port In the barrel as the plunger continues to move down the delivery cycle is completed Injection Pressure End of First Injection Step 3 Second Injection Step 4 Without Split Shot With Split Shot ...

Page 24: ... all previous DIT engines 0 rlng will fit loosely In groove 011 Resnvalr The new reservoir has the fuel filter assembly mounted to It via two bolts that pass through the housing Note These bolts are not open to oil and must be removed for removal and installation of fuel filter assembly In chassis fuel filter assembly removal does not require reservoir removal The oil reservoir Is now a two piece ...

Page 25: ...ent temperatures The fuel heater enables at temperatures Jess than 45 F 7 C and disables at 75 F 24 C Fuel Pre aure R aulalar Fuel Is returned to the tank via a fuel pressure regulator and fuel return line When reinstalling regulator tighten bolts to 50 70 lbf ln 5 6 7 9 Nm Fuel pressure is regulated to a minimum of 30 psi independent of engine speed Spool and spring areserviceable not shown 24 ho...

Page 26: ...Injectors Fuel Water Drain Ro on l For service all parts of the assembly are available separately To remove the fuel drain remove Ule four retaining screws tilt the drain away from the housing and pull downward When servicing tighten retaoning screws to 20 25 lbflin 2 3 2 8 Nm Fuel Heater Water In Fuel Sens u Re ewal The fuel heater connector and water in fuel sensor are combined on one unit To re...

Page 27: ...etaining screws to 20 25 lbl ln 2 3 2 8 Nm r l FUt Staadplpe s vlce To remove the fuel stan lptpe first remove the fuel heater element as shown above lhen pull the standpipe straight oot When installing be sure to install spring and valve Fuel rut s 1 r te The fuel fiHer assembly is shown here completely disassembled 28 Fuel heater Standpipe Lid Fuel liltar elemant Fuel filter lid seal Fuel liltar...

Page 28: ...uel filter s fuel supply and return lines are a one piece assembly Fuel Chock Valve The new fuel system Incorporates a fuel inlet check valve In the fuel supply lilting to each cylinder head The check valVe Insures that there is a constant and steady fuel pressure in the head lor fuel delivery It fuel pressure IS low In one head and normal on the other then inspect the check valve lor debris rl no...

Page 29: ...lugged passage at the end of the head opposUe the fuel supply line Fuel pressure should not drop below 30 pal It is not uncommon to see fuel pressures as high as 80 psi On Econoline the lett head should be checked tlrst The alternator and bracket must be removed to gain access to Ihe fuel pressure fitting on the right head Fuel Preuun Check In Left Head To check pressure in the left head install a...

Page 30: ...auge Tool 014 00761 High Pressure Oil Line Snap Ia Cannect Fillings The fittings allow the high pressure oil lines to be connected to the high pressure pump and heads simply by pushing them Into place Note Whenever high pressure system is opened air enters the system and the vehicle needs to be driven to remove the air High Pressure Oil Lines Note Push the lines Into the fittings until you hear fe...

Page 31: ...Preuure Black 011 Tul Theblockoff tools are alsoola snap to oonnect style so thallheY can be oonnected to the high pressure oil lines on the engines The tool part number for the block off plug is 303 628 and the ICP adapter is 303 627 These tOOls are necessary to accurately diagnose the ICP system during hard starVno start diagnosis 30 Insert disconnect tool here to release Essential tool 303 625 ...

Page 32: ... Only The MAT sensor is used to control fuel and timing when intake air iscold and adjusts as air temperatures warm up Manifold Absolute Pressure Sensor The MAP sensor now sends an analog signal to the PCM instead of the digital signal previously used The sensor is mounted to the heater and air conditioner plenum on the passenger side of the engine compartment 31 ...

Page 33: ...ensor is C93 The engine serial number break for this sensor is 623916 See CAMP sensor usage chart on page 45 for information regarding different CAMP sensors and their Identification Exhaust Baok Prauun Senaar The exhaust baCk pressure sensor has been relocated to the front of the oil reservoir The tube has been redesigned to accommodate the new sensor location 32 Part nwnber sultix location ...

Page 34: ... Flywhool Maunting Bolts Moin Bearing Cap Bolts lim step linol Rear Cover Mounting Bolls High Pressure Pump Gear Bolt Injector Prossure C ontrol Valve Body Injector Pressure Control Valve Nut Filtor Dral1t Volvo Rno ir Lid Scnwo To Insure proper torque aU threads must be cleaned and lightly lubrt04tod Apply Nover Son compound to threads of bolts prtor to ossamhly 1 htea d of apply Loctito 11277 Il...

Page 35: ...7 3L DIT P11wsr Slr11he Diagnostic Information Diagnaslic uida Scha alics and Fault Cade Ll l far all RIDdal yaar ara pravidad in tha back af this publicalian 34 ...

Page 36: ...n 4 5 Nm Fuel Prusvra Regulator Heusiag Rema al and lns tallalion Remove the two 2 1Omm regulator retaining cap screws Separate the regulator housing from the filter housing by approximately 1 4 to enable the fuel passage shOulder to properly clear the housing Slide the regulator hOuslng upward to disengage it from the metal fuel l1ne To reinstall slide regulator hOusing down to reengage rt wrth t...

Page 37: ...verse steps and torque to 18 241bf ln 2 2 7 Nm Pual Haatu Cannaclu R l lnalallatian Note W sensor must be removed before removing fuel heater connector jsoonnect the external one wire connector Rotate the fuel healer connector clOCkwise until II clears the lOCking tab Pull connector out and disconnect the Internal one wire connector To reinstall reverse steps 38 ...

Page 38: ...install drain valve reverse steps and tighten screws to 2Q 25 lbllin 2 3 2 8 Nm Stanol Pipe enol Heating Elaaant Ra nal enol lnatallatioa Drain fuellrom filler housing Remove fuel filler lid and filter element Note Stand pipe Is plastic and has tell hand threads Using a 7 8 crows foot remove stand pipe by rotating It in a clockwise direction Disconnect the internal one wire connection at the fuel ...

Page 39: ...in was redesigned to replace the cam follower guides and retainer to redesigned cam follower guide assemblies which bolt directly into the crankcase to hold the follower in place The redesigned roller follower guide assemblies are now held in place with a capscrew for each pair of tappets which has led to the etimination of the roller follower guide retainer This change occurred at engine serial n...

Page 40: ... the front cover beginning w h engine serial number 201681 through engine serial number 375549 The front COYer was redesigned starting with engine serial number 375549 to help keep the oil pump primed for initial start up To accommodate lhis change the pump inlet port was rotated oo which moVed the pickup tube from the left to lhe right The front oil COOler header gasket was also redesigned becaus...

Page 41: ... ring sealed engine oil pressure sensor and lnspectoo plug as sealing enhan emenls Oil Paa Due 10 the relocation of the pickup tube the Otl pan baffle was redesig ned to allow the pk kup tube to pass through il to the bottom of lhe pan This was done as of eng ne serial number 375549 40 ____ One pieca molded gaskel 0 ring seal 0 ring seal ______ 1997 Model year Pra 1997 Modal year Standpipe locatio...

Page 42: ...ollowed by a larger quanmy of luel to complete the injection cycle During the 1997 model year Econoline utilized the Split Shot injectors In all Federal and California calibrations Rate shaping of Injection proVIdes for a longer duration of tile injection process providing a cleaner quieter bum Federai P Senes 49 State and Canada injectors were unchanged through the 1997 model year Note Injector s...

Page 43: ...1995 model year engines starting with serial number 187100 up to serial number 201680 the high pressure pump did have a drain check valve and an integral edge filter The edge filter was deleted from the Injection pressure regulator On 1996 model year engines starting with senal number 201681 the high pressure pump does not have a drain check valve but continues to have an ontegral edge filter Hl1h...

Page 44: ...ed correctly and no damage occurs to the front cover due to Incorrect installation Wlrin1 Harnaaa and law Pl111 Ratay The wiring harness was redesigned starting with serial number375549 to Incorporategold plated terminal pins to Increase reliabilityand meet OBO II stancla tls Thesensors and connectors that received the gold pins were CMP EBP ECT and ICP The UVC harness _ oncorporates a wireclip in...

Page 45: ...p is to be used on all 1996 and 1997 model year engines with serial numbers starting with 201681 through January 1998 production The FSTZ 8501 ARM is to be used on all engines from the 1994 model yearserial number 000501 through 1995 model year serlal number 201681 The FS pump comes with a bolt pacl age that is to be used to mount the replacement pump The FS pump also incotpOrates a larger bealing...

Page 46: ...suffix is tin plated and 1 152 t 0 006 in length This sensor has improved circuitry over the C96 sensor The C98 sensor is identical to the C97 except for the length it is 1 142 0 004 In length Due to the change in wiring harnesses three new sensors were made with gold pins The C91 sensor is 1 152 t 0 006 in length which was used in engine serial numbers 375549 through 408253 and the C92 is 1 142 t...

Page 47: ... As of engine serial number 286299 the oil pressure regulator and the oil filter bypass is held in with a c clip instead of staking Note Bypuaa valves should be In place to avoid engine damage 4 6 Oil pressure regulator with C clip Staltad ail pressure regulator ...

Page 48: ...umps and may be used interchangeably Oil Pen s Unt When reseal1ng the Oil pan make sure that the silicone rs apphed property Extra sealant is required at the ends of the radius on each end of the pan Make sure to avoid applying too much sealant 10 pan rails since il can fall off in the pan and plug the oil piok up tube Always use dowels make locally to locate the pan during Installation Whenever l...

Page 49: ... oveffueling type corJCem exisls such as a knock smoke orfuel out the tajpope renlOIIe the loose lnjec lorslor inspeclion and repair as neoessary Remember whenservicing 1njectors to lubricate the boh threads to obtain theproperdamp load and avoid 011ertlghtnlng the bollS since Injector damage can oocur Oil Capadly Theoil capacity on all DIT engines Is 14 quarts when dlanglng the oil and finer When...

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Page 52: ...I 1 KEYPWR I CMP SSntt i l m 1 et IP Otow Plug Rtlfty _ ___ _ __ IPA BEQ 12 VObiS 0 120 Oflt EDC BA W 0 11 1 0 17 24 _ CJ O_ FOCS EFF cl ck IOM Connector E l I 2 V M J BUS A t SUS YSS vss ttL CPP 5witch lt_ VDWit 3 BPA switch KEYPWA I ICont ol it I c Sd mWR a l if 1 ffiA t l 10 ICASE t t viWR 9mmaf j ___ _ II RLC o _ _ _ ___ _ s t t 1 t l l PWAGHD 71 117 c Conrrol 3 FEPS EPA 06tted Unft F ttqu y o...

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Page 54: ...ccessoM off Latch STAR test button on ground STI Tum key to ON position After fasr code transmission depress and release brake to aborl slOw codes Depress and release a erator pedal to start tssl Codes will bedisplayed at end o1 test Tasl can be repeated by depressing and releasing accelerator pedal twice Note The engine will run rough during the KOER Stsndsrd snd Cylindsr Contribution Tests KOER ...

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Page 61: ...Econoline ALL F 250 F 350 California only pe y ___ _ _ Open or lflotl drWl lallir PCM Mllure orfaJecl tO IIC IIYIM swtiCt l dl lltlg KOER twlldl INI Crl illle control anc t 8F A c oc ee d be Mt on y n OI I not cn tOOMrol _ _ noid IIY PCM ...

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Page 64: ...I I I EPR 42Way onnecto Oot1ed Unet F cy Ot Switch Foo tlona R Q 12 VOLTS BLACK GROUND CIRCUIT GREEN SIGNAL CIRCUIT yeh clp Mounted Components PCM Connector i ms r _ _ y n_ _ i 2L lt VPWA IDM _ L __ Orienl ttion look ng ifl10 h tide ofton1 or PURPLE e HIGH VOLTAGE BLUE e VBEE CS VOLTS Cab Mounted Components KAPWR I AP I so Data 1 rn1 KEYPWA ...

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Page 68: ...Power Stroke 1999 8 1998 1 2 E Series and 1999 F Series r ...

Page 69: ...OL SYSTEM ELECTRONICS DIAGNOSTIC GUIDE 08011 Mil lllumln tlon CX Ut tttt 2nd cone fv fault FU EM MIL l lul ftlndon occurs att r ttl fault Transm 1on Control Indicator Light TCtl _whentauh It 1 TCIL ontt t IU Ol f lt 69 ...

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Page 72: ...M DT f fllf 0 11t C l tteo t t11 M Na IIWII __ T J M IJOiiiiiiii Oif mt I Wf Otlt O C fW CO I _ ON I t NOS Tooll DIU u l II l l j I HCII _ _ _ _ llldNI l f I __ ___ I _ I _ __ _ _ _ __ _ __ I I __ _ c __ _ _ _ _ I I Vhlfi II IW ClfiWtiMt II CW 1 1111 _ 00lOf N OHrt Qf AIW fltNit Hflll _ eW _ lll pcloo4fM Cl t WM _ 1 t 0 OoiP t 10 Ito H ll OWfll OII T O I f r 00t I IN CMti SfOO I _ tot _ _ _ _ o _ ...

Page 73: ... IIIMIII Il W ItOoii IWI fl I Vlau I f c u co tr W on I l tNI EOTtl JO lnllb Rasalkdon I f l VC 01 1111 0 00 w cc IIIOfll _________ _ _ pt PI I 1 I I I a _ICOEO 0 t i r I 1 LU NGI t _ I oro ____ _ fWI WO I Dol tnt _ NHJ T_ _ o Y M I 1 I lllwi Ia IWO W lOt Nlw t fltt rfotott Conti IUOI I TtWblt COGM t KOlA On o m ld TMI Jj 1 _ o asr 1 1o M T flfUJ ore _ _ _ I I I _ raton _ eo r t _ __ OMII I o flll...

Page 74: ... Hall Effect sensor generates a digital on off signal that Indicates speed and also engine timing The signal is created by a switching action caused by the passing of a vane thru a positive and negative voltage potential When the vane is between this potential a signal is created When the gap in between this potential is open no signal is generated The wider the vane the longer the duty cycfe of t...

Page 75: ...as a variable voltage divider The wiper arm IS mechanically connected to the component desired to be nsed Potentiometers have three connections Vref signal out and ground Puhe Width The length of time an actuator such as an injector remains energized Split Shot Injector Prime Split shOt Injectors provide improved exhaust emissions and quiets engtne operation by tailoring the injection of fuel With...

Page 76: ...ulator 24 35 restriction sensor 35 service 25 26 35 37 standpipe 26 water drain 24 25 37 water sensor 25 36 Fuel inlet check valve 27 Fuel supply tines 27 41 Fuel system diagram 28 G Glow plug relay 43 H High pressure oil pump 42 Horsepower 5 I Injector 21 23 41 torque 48 o rings 23 spm shot prime 21 22 41 Injection control regulator 43 rings 43 Intake cover 16 48 Intake hoses 16 47 0 Oil cooler h...

Page 77: ...4 Thermostat housing 11 Torque data 33 Turbine inlet and clamp 10 20 Turbo 13 15 20 Removal 17 20 u Under valve oover harness UVC 7 43 v Valve cover gasket 7 Valve tXNer gasket breakout tool 8 w Waste gate actuator t6 control 15 Water pump 11 44 Water pump pulley 11 78 ...

Page 78: ... 7 3 DI T Power Stroke Direct Injection Turbocharged Diesel Engine FSC 12922JA ...