Ford 60 Service Manual

162
163
164
 • There is now a new test incorporated into
the WDS.
 • This test allows the technician to disable one
injector at a time and monitor pids to identify
weak injectors.
 • While disabling injectors watch the Mfdes
pid. The injector(s) that have the least effect
on Mfdes while being disabled could be the
weak injector.  • When diagnosing a power or ground issue
be aware that there is a 12 way connector
that feeds power and/or ground to the 
following components.
 • FICM
 • IPR
 • EGR
 • The 12...

166
167
Oil Aeration Test
 • If oil aeration is suspected, install a valve
and hose into the oil system at either the
EOT or EOP sensor.
 • Note: All materials being used should be
rated above 300 psi and 300°F.
 • Run the engine until the oil is at a normal
operating temperature.
 • Run the engine at high idle for approximately
one minute and then return to idle.
 • With engine at idle open the valve and drain
a sample of oil into a clear container and
observe for air or foam in the oil.
 • Caution: Oil...

168
169
 • Every time the key is cycled to the on 
position, the injectors should buzz.
 • If no buzz is heard one of the following 
conditions may be present:
a) No power or ground to the FICM or
PCM.
b) No CAN communication between the
FICM and the PCM.
c) V-ref shorted to ground.
d) Bad PCM or FICM.
e) All injectors bad or wiring to all
injectors bad (not likely).
 • If the injectors do buzz and all conditions are
met for the engine to run but the injectors do
not fire during crank, check the FICM...

APPENDIX
83
TABLE OF CONTENTS
Torque Charts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Hard Start/No Start Diagnostics  . . . . . . . . . . . . . . . .88
Performance Diagnostics  . . . . . . . . . . . . . . . . . . . . .89
Wiring Diagrams  . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Diagnostic Codes  . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Glossary  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Index  . . . . . . . . . . . . . . . . ....

SPECIAL TORQUE CHART
84
Air inlet duct clamp ........................................................44 lbf/in 5 Nm
Camshaft follower retaining device bolt ..........................10 lbf/ft 13 Nm
Camshaft position (CMP) sensor ......................................96 lbf/in 11 Nm
Camshaft thrust plate mounting bolts ..............................23 lbf/ft 31 Nm
Connecting rod bolt (Initial) ............................................33 lbf/ft 45 Nm
(Final)...

SPECIAL TORQUE CHART
85
Lower crankcase outer bolts ............................................18 lbf/in 24 Nm
Oil cooler mounting bolts (M8) ........................................16 lbf/ft 22 Nm
(M6) ........................................89 lbf/in 10 Nm
Oil filter cap ..................................................................18 lbf/ft 24 Nm
Oil filter housing bolts ....................................................11 lbf/ft 15 Nm
Oil filter stand pipe bolt (new)...

SPECIAL TORQUE CHART
86
Cylinder Head Bolts
 • Step 1: Torque the M14 (1-10) cylinder head bolts to 65 lbf/ft (88 Nm) in the numerical sequence shown.
 • Step 2: Torque the M14 cylinder head bolts 1, 3, 5, 7, & 9 to 85 lbf/ft (115 Nm) in the numerical sequence shown.
 • Step 3: Tighten the M14 cylinder head bolts an additional 90o 
clockwise in the numerical sequence shown.
 • Step 4: Tighten the M14 cylinder head bolts an additional 90o 
clockwise in the numerical sequence shown.
 • Step 5: Tighten the...

SPECIAL TORQUE CHART
87
High Pressure Oil Rail Bolts
 • Step 1: Install bolts 1, 2 and 3 finger tight.
 • Step 2: Press rail down until seated.
 • Final step: Install remaining bolts and torque to 96 lbf/in (11 Nm) in sequence shown above.Figure C
6 1
4 2
8 7 3
5
1
2
3
4
5
6
7
8 910 1112 1314 15
16
Figure D Intake Manifold Bolts
 • Step 1: Install bolts 1 through 8 finger tight.
 • Step 2: Torque bolts 9 though 16 to 8 lbf/ft (11 Nm).
 • Final step: Torque all bolts to 8 lbf/ft (11 Nm) in the numerical...

HARD START/NO START DIAGNOSTICS
88
CUSTOMER NAME
F-Series/Excursion Powerstroke2003.25
MODEL YEAR VEHICLE SERIAL N0.(VIN)
6.0L Power Stroke Diesel Engine Diagnostic Guide
CHASSIS STYL
E
Customer Concerns  (Please list in this box)
DEALER NAME1863 CLAIM NUMBER DATE
ENGINE SERIAL NUMBER ODOMETER
TYPE OF SERVICE
VEHICLE GVW TRANSMISSION AMBIENT TEMPERATURE
PERSONAL COMMERCIAL P & A
CODE
  -NOTE-
IF CONCERN IS FOUND, SERVICE AS 
REQUIRED. IF THIS CORRECTS THE 
CONDITION, IT IS NOT NECESSARY TO 
COMPLETE THE...

PERFORMANCE DIAGNOSTICS
89
CUSTOMER NAME
F-Series/Excursion Powerstroke2003.25
MODEL YEAR VEHICLE SERIAL N0.(VIN)
6.0L Power Stroke Diesel Engine Diagnostic Guide
CHASSIS STYLE
Customer Concerns  (Please list in this box)
DEALER NAME1863 CLAIM NUMBER DATE
ENGINE SERIAL NUMBER ODOMETER
TYPE OF SERVICE
VEHICLE GVW TRANSMISSION AMBIENT TEMPERATURE
PERSONAL COMMERCIAL P & A
CODE
  -NOTE-
IF CONCERN IS FOUND, SERVICE AS 
REQUIRED. IF THIS CORRECTS THE 
CONDITION, IT IS NOT NECESSARY TO 
COMPLETE THE REMAINDER...