Ford 60 Service Manual

135
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...

137
138
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...

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)...

143
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...

146
147
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...

150
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...

152
153
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...

156
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...

158
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...

160
161
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...