Ford 60 Service Manual

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136
Injector O-ring: Replacement Injector Removal: cont.
Injector Removal: cont.
UNIQUE SERVICE PROCEDURES
70
 • The injector connectors on the 6.0LPower
Strokeare locked into the rocker arm carrier.
 • To disconnect the external engine wiring 
harness from the injector push in on the
spring loaded metal clip on the harness.
 • To remove 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.
 • To remove the injector loosen the T40 torx
socketed bolt that holds the injector in place
this will also unseat the injector from it’s
bore.
 • Note: Do not use air tools to remove the
injector.
 • Carefully lift the injector from the bore.
 • 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.
 • Note: Make sure that the copper gasket at
the bottom of the injector has not fallen
into the injector bore.
 • Once the injector has been removed, 
carefully remove the external o-rings.
 • Note: Be careful not to scratch the 
injector body during removal or the
replacement o-rings may not seal.
 • Carefully install new o-rings on the injector
body.
 • Note: If the o-ring is cut or nicked during
assembly it will have to be replaced.
 • Note: Do not pull on the wires while
working with the injector.
134
INJECTORINJECTOR
INJECTOR HOLD DOWNINJECTOR HOLD DOWN
FUEL UPPER
FUEL LOWER
COMBUSTION GAS SEAL 
						

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139
Injector Installation: cont. Injector Installation
Injector O-ring Replacement: cont.
UNIQUE SERVICE PROCEDURES
71
 • 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.
 • 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.
 • 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.
WELL SOCKET9mm DEEP
INTERNAL UPPER O-RINGINTERNAL UPPER O-RING
IS NOT REMOVABLEIS NOT REMOVABLE
LUBRICATE O-RINGS
FUEL INLET
LUBRICATE O-RINGSLUBRICATE O-RINGS 
						

							140
141
142
Cylinder Head - Rocker Fulcrums Rocker Arms / Bridges
Cylinder Head - Rocker Carrier:
Removal
UNIQUE SERVICE PROCEDURES
72
 • Before 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.
 • The rocker arms must be installed in their
original position during reassembly.
 • 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.
 • 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 and torque to specifications.
HEAD BOLTSHEAD BOLTS
HEAD BOLTSHEAD BOLTS
Note: If the rocker arms and/or valve bridges are not correctlyNote: If the rocker arms and/or valve bridges are not correctly
installed, premature valve train wear may result.installed, premature valve train wear may result.
INTAKE ROCKERINTAKE ROCKEREXHAUST ROCKEREXHAUST ROCKER
VALVE BRIDGE
VALVE BRIDGE
DOWELDOWEL
ROCKER FULCRUM
ROCKER FULCRUM 
						

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145
EGR Valve: Removal Glow Plug / Injector Sleeve:
Installation Glow Plug / Injector Sleeve: Removal
UNIQUE SERVICE PROCEDURES
144
73
 • 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.
 • 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.
 • 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.
TOOL #303-760 
						

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148
Crankcase Ventilation: Removal / Oil
Carryover Turbocharger Oil Supply: Removal EGR Cooler: Removal & Installation
UNIQUE SERVICE PROCEDURES
 • Before removing the EGR cooler you must
first drain the coolant from the cooling 
system.
 • To disconnect the hose that supplies coolant
to the EGR cooler, rotate it and pull till the
tabs release.
 • Both the inlet and outlet for exhaust gasses
are sealed with metal gaskets.
 • The coolant connections are sealed with 
o-rings.
 • Use tool #303-755 to remove the oil feed to
the turbocharger that is connected to the oil
filter base.
 • The connection at the turbocharger is a 
bolted flange and is sealed with a gasket.
74
 • To disconnect the crankcase ventilation tube
from the engine, remove the air inlet tube
from the compressor inlet and rotate the
vent counter clockwise until it releases.
 • Note: Since the 6.0LPOWER STROKE
uses a closed crankcase ventilation 
system, it is normal to see oil carry over
in the intake air system.
EGR COOLER HOSE
EGR COOLER HOSE
TOOL #303-755TOOL #303-755
COMPRESSOR OUTLETCOMPRESSOR OUTLET
OIL SUPPLY TUBEOIL SUPPLY TUBE
CRANKCASE BREATHER HOSE
CRANKCASE BREATHER HOSECOMPRESSOR
INLET HOSE 
						

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151
IPR Valve: Removal
 • To remove the IPR valve use the IPR socket
tool #303-769 and turn counterclockwise.
 • Note: The connector for the IPR might hit
the cylinder head. If this occurs the coil
body can be repositioned on the valve.
Intake Manifold Turbocharger Oil Drain Tube:
Removal
UNIQUE SERVICE PROCEDURES
149
75
 • The turbocharger oil drain is located under
the turbocharger and is sealed with o-rings.
 • To remove the drain tube pull it forward, out
of the high pressure pump cover.
 • When reinstalling the intake manifold, the
locating tabs on the intake manifold gasket
should face up and toward the center of the
engine.
 • There is a port on the intake manifold for
cooling system deaeration that returns to the
coolant reservoir.
GASKET LOCATING TABGASKET LOCATING TAB
INTAKE PORTS INTAKE PORTS
TURBO MOUNTING
PEDESTALTURBO OIL DRAIN
TUBE
TOOL #303 769TOOL #303 769 
						

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154
Front Cover: Dowel Locations Front Cover: Removal
High Pressure Pump Cover: Removal 
UNIQUE SERVICE PROCEDURES
 • 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.
 • When reinstalling the cover, be sure to 
lubricate the discharge tube o-ring before
installing the cover.
 • 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.
 • The front cover is located to the crankcase
with dowels.
 • 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
CUT AT THESE TWO PLACESCUT AT THESE TWO PLACES
DOWELS
DOWELS
HIGH PRESSURE
PUMP COVERHIGH PRESSURE
PUMP COVER
DISCHARGE TUBE DISCHARGE TUBE
O-RING 
						

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157
Glow Plug / Buss Bar: Removal
 • In order to access the glow plugs, the glow
plug buss bar must be removed.
 • To remove the glow plug buss bar pull out on
the bar evenly.
 • After the buss bar has been removed, the
glow plugs can be accessed through the
rocker carrier.
 • To reinstall the buss bar push evenly on the
bar to seat the o-rings on each connection.
 • Note: Do not hit the buss bar with a 
hammer, damage may occur.
Front Cover: Sealant Application Front Cover: Gerotor Oil Pump
UNIQUE SERVICE PROCEDURES
 • 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.  • The lube oil pump is located to the front
cover by dowels and sealed with a push in
place gasket.
155
77
PRESS IN PLACE GASKETPRESS IN PLACE GASKET
DOWELS
DOWELS
BLOCK
BED PLATEBED PLATE
UPPER PANUPPER PAN
LOWER PANLOWER PANSEALANT LOCATIONSSEALANT LOCATIONS
GLOW PLUG BUSS BARGLOW PLUG BUSS BAR
CONNECTOR PASS THROUGH HOLESCONNECTOR PASS THROUGH HOLES CONNECTOR O-RINGSCONNECTOR O-RINGS 
						

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159
 • 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
notremove the six bolts in the
primary flange. If the bolts are removed
the crankshaft will have to be replaced or
repeated seal damage will occur.  • 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.
Crankshaft Primary Flange Crankshaft Rear Seal Dust Cover
UNIQUE SERVICE PROCEDURES
78
DUST SHIELD DUST SHIELD
PRIMARY FLANGE PRIMARY FLANGE
DO NOT REMOVE
THESE BOLTS DO NOT REMOVE
THESE BOLTS 
						

							160
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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 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.
Air in Fuel
GENERAL DIAGNOSTICS
79
 • 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.
VGTCV DISCONNECTED VGTCV DISCONNECTED