Ford 60 Service Manual

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12
1) Rocker Arm Carrier
2) Bed Plate
3) Glow Plug Buss Bar 1) FICM
2) CMP Sensor
3) Oil Level Gauge
4) Crankcase Ventilation
Left Rear of Engine Left of Engine
COMPONENT LOCATIONS
10
1
3
2
1 3
4
2 
						

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14
Right Rear of Engine
1) Block Heater
2) Turbine Outlet
3) Exhaust Connection to EGR Cooler
4) Exhaust Expansion Joint 1) Exhaust Expansion Joints
2) Heat Shields
3) Lifting “Eye”
4) Serial Number
5) ICP Sensor & IPR (Behind ICP)
Rear of Engine
COMPONENT LOCATIONS
11
1
2
2
3
4
1 3
2
5
4 
						

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16
1) Heater Return
2) EGR Throttle Actuator 1) CKP Sensor
2) Glow Plug Control Module
Right Front of Engine Right Side of Engine
COMPONENT LOCATIONS
12
12
1 2 
						

							17
18
Top of Engine
1) EGR Valve
2) EGR Cooler
3) Turbocharger Compressor Outlet
4) IAT2 Sensor
5) EOP Switch
6) EOT Sensor 1) Oil Filter
2) Turbocharger Oil Supply Line
3) EVRT/VGT Control Valve
4) Injector Connectors
5) Secondary Fuel Filter
6) EGR Cooler Coolant Deaeration Port
Top of Engine
COMPONENT LOCATIONS
13
1 6
5 2
3
4
2
34
6 5
1 
						

							19
20
21
 • The geartrain for the crankshaft, camshaft,
and high pressure pump are located in the
rear of the engine under the rear cover.
 • This allows the high pressure pump to be
mounted inside the engine and also reduces
geartrain noise.
Rear Geartrain Cylinder Head
Rocker Carrier
6.0LPOWER STROKEFEATURES
14
 • The aluminum rocker arm carrier is mounted
on top of the cylinder head and is held in
place by the cylinder head bolts.
 • The rocker arm carrier provides the 
mounting location for all of the rocker 
fulcrums.
 • The carrier also provides the connector pass
through for the injector and glow plug.
 • The 6.0LPOWER STROKEuses a four (4)
valve per cylinder head design to increase
air flow and efficiency.
 • For identification, the exhaust valves are
smaller than the intake valves.CONNECTOR PASS THROUGH CONNECTOR PASS THROUGH
CYLINDER HEAD BOLTS
CYLINDER HEAD BOLTS
ROCKER ARMS
ROCKER ARMS
EXHAUST VALVES
INTAKE VALVES
INJECTOR NOZZLE
GLOW PLUG
HIGH PRESSURE PUMP GEAR HIGH PRESSURE PUMP GEAR
CAMSHAFT GEAR
CRANKSHAFT GEAR 
						

							22
23
24
Normal Heat Treatment Discoloration
 • The bearing surfaces on the crankshaft are
induction hardened.
 • During the hardening process the 
surrounding areas of the crankshaft discolor.
This condition is normal.  • A single mass flywheel is used on the 
F-450/550 Superduty trucks.
 • The single mass flywheel can be identified
by the absence of the above mentioned
parts and that it is machined from one solid
part.  • The 6.0L Power Stroke uses two different 
flywheels for the manual transmission.
 • A dual-mass flywheel is used on the 
F-250/350 Superduty truck.
 • The dual-mass flywheel can be identified by
springs located around the flywheel on the
engine side.
 • It can also be identified by an extra ring of
bolts on the transmission side of the 
flywheel that holds the two masses together.
 • From the side it can be identified by the 
separation between the clutch surface and
the starter ring.
Single Mass Flywheel Dual Mass Flywheel
6.0LPOWER STROKEFEATURES
15
RING OF BOLTS
CLUTCH SURFACE
STARTER RING
SPRINGS
DISCOLORED AREA DISCOLORED AREA 
						

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							 • The modular water pump can be serviced
without disconnecting radiator hoses.
 • Both the glow plug sleeves and the injector
sleeves are stainless steel.
Cooling System Features
COOLING  SYSTEM
Cooling System Flow
Cooling System Features
 • Modular Water Pump
 • Stainless Steel Injector Sleeves
 • Stainless Steel Glow Plug Sleeves
25
17
26 
						

							27
28
29
Cooling System Flow: Oil Cooler Cooling System Flow: Back of Front
Cover Cooling System Flow: Front Cover
COOLING SYSTEM
18
 • Coolant is drawn into the inlet of the front
cover and then flows from the water pump
through the front cover to the crankcase.
 • Coolant is also routed from the front cover
into the crankcase to a passage that feeds
the oil cooler.
 • Return coolant is directed to the thermostat
by the front cover. If the thermostat is open,
coolant flows to the radiator to be cooled. If
the thermostat is closed, coolant is returned
to the water pump via a bypass circuit in the
front cover.
 • Coolant is sealed via a silicon in metal one
piece gasket and is directed out of the front
cover through three (3) passages.
 • Two of the passages route coolant to the
crankcase to cool the cylinder walls and
cylinder heads.
 • The third passage routes coolant  to the oil
cooler via a passage in the crankcase.
 • There are two passages for coolant to return
from the crankcase into the front cover.
 • Coolant is directed out of the crankcase and
into the oil filter base at the front of the
engine.
 • The oil filter base routes the coolant into the
front of the oil cooler then toward the back of
the engine.
 • Once the coolant has passed through the oil
cooler it is directed out of the oil filter base
to the EGR cooler.
 • Note: There are weep holes in the oil filter
base that allow coolant or oil to seep out
side of the filter base if an oil cooler seal
is damaged.
IN
ININ
IN
OUT
OUT
OUT
OUT 
						

							30
31
32
Injector Sleeve Water Pump & Front Cover
Cooling System Flow: EGR Cooler
COOLING SYSTEM
19
 • Coolant flows out of the filter base and into
the EGR cooler through a tube that directs
the coolant to the back of the EGR cooler.
 • Coolant flows through the EGR cooler and
removes heat from the exhaust gasses
before the exhaust arrives at the EGR valve.
 • Coolant exits the front of the EGR cooler and
enters the coolant passage of the intake
manifold. The intake manifold directs the
coolant back into the front cover.
 • The water pump, (hub and impeller) is
mounted into the front cover which is the
housing for the water pump.
 • The water pump impeller pulls coolant from
the center of the housing and pushes it 
outward.
 • The water pump has a built in reservoir to
catch small amounts coolant that during 
normal operation of the engine may seep
past the seal.
 • Note: The water pump impeller may be
damaged if dropped or hit by a hard
object.
 • The 6.0LPower Strokeuses stainless steel
injector sleeves to seal coolant from the 
injector and to transfer heat from the injector
to the coolant.
 • The injector sleeve is replaceable. See
unique service procedures or service 
manual for more details.
IMPELLER
IMPELLER
RESERVOIR RESERVOIR
INJECTOR SLEEVE
INJECTOR SLEEVE