Ford 60 Service Manual

							FORWARD
This publication is intended to provide technicians and service personnel with an overview of technical advancements in the
6.0LPOWER STROKEDiesel 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 WARNINGSthat 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.
Be sure that the ignition switch is always in the OFFposition, 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 PARKunless 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. 
						

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							6.0LPOWER STROKE
3
TABLE OF CONTENTS
OVERVIEW  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Features  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Horsepower & Torque  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Identification  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
COMPONENT LOCATIONS  . . . . . . . . . . . . . . . . . . . . . .9
Features  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
COOLING SYSTEM  . . . . . . . . . . . . . . . . . . . . . . . . . .17
System Flow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Water Pump  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
LUBRICATION SYSTEM  . . . . . . . . . . . . . . . . . . . . . . .21
System Flow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
FUEL SUPPLY SYSTEM  . . . . . . . . . . . . . . . . . . . . . . .27
System Flow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Check Valve  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
AIR MANAGEMENT SYSTEM  . . . . . . . . . . . . . . . . . . . .31
System Flow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
VGT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
EGR  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
FUEL MANAGEMENT SYSTEM  . . . . . . . . . . . . . . . . . .39
High Pressure Oil System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
System Flow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Fuel Injectors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Stages of Injection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
ELECTRICAL COMPONENTS  . . . . . . . . . . . . . . . . . . .49
Sensors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Actuators  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Other Electrical Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
UNIQUE SERVICE PROCEDURES  . . . . . . . . . . . . . . . .69
GENERAL DIAGNOSTICS  . . . . . . . . . . . . . . . . . . . . . .79
APPENDIX  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 
						

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							1
Direct Injection
Turbocharged Diesel
Engine
6.0LPower Stroke 
						

							 • The 6.0LPower Strokecreates 325 
horsepower at 3300 RPM and 560 ft/lb of
torque at 2000 RPM.
 • Note: Torque has increased and occurs at
lower engine RPM than previous models.  • This publication is not intended to replace
the Service Manual but to introduce the 6.0L
Power Strokeengine.
Horsepower & Torque Engine Features 6.0LPower Stroke Overview
6.0LPOWER STROKEOVERVIEW
6.0LPower StrokeDirect Injection
Turbocharged Diesel Engine
Overview
 • Engine Features
 • Horsepower & Torque
 • Engine Specifications
 • Physical ID
 • Labeling
2
Engine Features
 • Variable Geometry Turbocharger
 • Digital Fuel Injection
 • 4 Valves per Cylinder
 • Reusable Gaskets
 • Rear Gear train
 • Dual Timing System
3
6
 • The 6.0LPower Strokehas been designed
to meet the customers’ expectations of high
horsepower and torque over a wide RPM
range.
 • The 6.0LPower Strokehas also been
designed to meet the tougher emissions
standards set by the government.
 • 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.
0 100
200 300 400 500
600
500 1000 1500 2000 2500 3000 3500 4000
e ngine  s pe e d [rpm ]
Torque [ft-lb]Po w e r  [ b h p ]4
Horsepower & Torque Chart 
						

							6.0LPOWER STROKEOVERVIEW
6.0LPower StrokeDiesel Specifications
Engine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel, 4-Cycle
Configuration  . . . . . . . . . . . . . . . . . . . . . . . . .4 OHV/1 Cam-in-Crankcase-V8
Displacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365 cu. in (6.0 L)
Bore & Stroke . . . . . . . . . . . . . . . . . . . . . . . . . .3.74 X 4.134 in (95 X 105 mm)
Compression Ratio  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18.0:1
Aspiration  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VGT/CAC
Rated Power @ 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 lb. (438 kg)
Coolant Flow  . . . . . . . . . . . . . . . . . .74.7 gal/min (282.8 L/min) @ 3300 RPM
Air Flow @ RPM  . . . . . . . . . . . . . . . . . .732 CFM (20.7 m
3/min) @ 3300 RPM
Exhaust Flow @ RPM  . . . . . . . . . . . . .1499 CFM (42.4 m
3/min) @ 3300 RPM
Oil Flow @ RPM  . . . . . . . . . . . . . . . . . .18.5 gal/min (70 L/min) @ 3300 RPM
Cooling System Capacity (engine only)  . . . . . . . . . . . . . . .11.1 qts. (10.5 L)
Lube-System Capacity (including filter)  . . . . . . . . . . . . . . . . .15 qts. (14.2 L)
Firing Order  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2-7-3-4-5-6-8
2
8
4
6
7
5
3
1 Front
LR
5
7
 • The 6.0LPower Strokeengine is a totally
new engine design that will provide improved 
performance, and cleaner emissions.
 • The cylinders of the 6.0LPower Strokeare
numbered from the front on the right side
1,3,5,7 and from the front on the left side
2,4,6,8.
Specifications 
						

							6
7
8
 • Another location for the engine serial 
number is a label on the FICM (Fuel
Injection Control Module).
 • The engine serial number label also states
the build location and build date of the
engine.
 • Another label on the FICM is the part 
number and the FICM calibration label.
Emissions Label Serial Number/FICM Calibration Label
Engine Serial Number
6.0LPOWER STROKEOVERVIEW
8
 • The engine serial number is located on the
left rear corner of the crankcase.
 • The engine serial number identifies the
engine family, build location, and the
sequential build number.
 • 6.0 - is the engine family identifier.
 • HU2U - is a manufacturing designator.
 • 6000173 - is a sequential build number.
 • States the horsepower rating for the engine,
programmed in the powertrain control 
module (PCM).
 • Depicts where the engine meets or exceeds
emission standards.
 • Shows the engine displacement.
 • Is affixed to the right hand valve cover
behind the glow plug control module. 
						

							9
10
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) 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 Front of Engine
COMPONENT LOCATIONS
9
1
22
35
4
1
2
3
4
5
6