Ford 60 Service Manual

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34
 • The coolant recovery bottle is located above
the left valve cover.
 • One of the ports on the bottle is attached to
the EGR cooler deaeration port. If this port
or hose is blocked, damage could occur to
the EGR cooler.
Coolant Recovery Bottle Glow Plug Sleeve
COOLING SYSTEM
20
 • Glow plug sleeves are used to keep coolant
from coming in direct contact with the glow
plugs and to seal coolant from the 
combustion chamber.
 • The glow plug sleeve is replaceable. See
unique service procedures or the service
manual for more details.
GLOW PLUG SLEEVE
GLOW PLUG SLEEVE
COOLANT RECOVERY BOTTLECOOLANT RECOVERY BOTTLE
TO EGR COOLER TO EGR COOLER 
						

							36
System Flow Lubrication System Features
LUBRICATION SYSTEM
 • The 6.0LPower Strokeuses an oil cooler
that is mounted in the valley of the engine
under the oil filter. There is also a oil 
pressure test port in the front of the oil 
cooler.
 • There are no oil passages located on the
outside of the crankcase. This reduces the
chance for oil leaks.
 • The oil filter is a canister style filter mounted
on the top of the engine, that drains to the
oil pan during servicing.
 • The gerotor oil pump and oil pressure 
regulator are both located in the front of the
engine behind the vibration damper.
Lubrication System Features
 • Integrated Oil Cooler
 • No External Oil Passages in Crankcase
 • Easy Access Canister Style Oil Filter
 • Front Oil Pressure Test Port
 • External Oil Pressure Regulator
35
21
OIL FILTER BASE
GEROTOR OIL PUMP
OIL PRESSURE
REGULATOR 
						

							Oil Pump
Oil Cooler
Oil Filter
Pump
Bypass
70 PSI Cooler
Bypass
25 PSIFilter
Bypass
20 PSI
Lube Pressure Oil System Schematic
T
T
T
T
T
T
T
T
T
T
T
T
T
TT
T
MB
MB
MB
MB
MB
CB
CB
CB
CB
CB
Tu r b o
CR
CR
CR
CR
CR
CR
CR
CR
Oil Reservoir
for High
Pressure
Pump 0.95 Qt.
To High
Pressure Oil
System
T= Tappet
CB = Cam Bearing
MB = Main Bearing
CR= Connecting Rod
= Piston Cooling Jet Right Bank
Left Bank
37
38
Oil Pan / Bed Plate Lubrication System Oil Flow
LUBRICATION SYSTEM
22
 • Oil is drawn from the oil pan through the
pick-up tube to the gerotor oil pump.
 • The oil pressure is regulated to 75 psi via
the oil pressure regulator relieving excessive
oil pressure to the inlet of the oil pump.
 • From the oil pump, oil is directed to the oil
cooler and then the to the oil filter.
 • From the oil filter the oil is supplied to four
(4) passages. One is to the turbocharger for
lubrication and VGT control via an external
line.
 • The oil also is provided to the oil reservoir
that supplies the high pressure oil pump.
 • The two (2) other passages are to the tappet
oil feed on the right and left banks. The 
tappet galleries also provide oil to the piston
cooling jets.
 • Cross drillings off of the right bank tappet
gallery feed the cam bearings, then the
crankshaft main bearings.
 • The crankshaft has cross drillings in it to
direct oil to each of connecting rod bearings.
 • The 6.0LPower Strokeuses a two piece oil
pan. The lower half is wider than the bottom
of the engine to increase its capacity. Due to
this wider oil pan, an upper oil pan is used to
adapt the lower pan to the bed plate. The
upper pan also acts as an oil baffle.
 • The upper pan is bolted to the bed plate.
The bed plate replaces the individual main
bearing caps. This one piece design results
in a more rigid bearing retaining system.
 • The pick-up tube is bolted to the upper pan
and oil is routed through the upper pan and
the bed plate to the front cover.
WIDER OIL PAN
UPPER OIL PAN
BED PLATE 
						

							39
40
41
Gerotor Oil Pump Oil Pressure Regulator
Pick-up Tube / Oil Aeration
LUBRICATION SYSTEM
23
 • The pick-up tube supplies oil from the oil pan
to the oil pump.
 • The pick-up tube is sealed to the upper oil
pan utilizing an o-ring. If the o-ring is 
damaged or missing, it could cause oil 
aeration and poor performance.
 • Oil aeration is the result of air being 
introduced to the lubrication system on the 
suction side of the system or by the 
breakdown of the anti foaming agents in the
oil. Oil aeration can cause low power and
poor idle.
 • A damaged or loose pick-up tube could also
cause oil aeration.
 • The oil pressure regulator is located in the
front cover just below the gerotor oil pump.
 • The oil pressure regulator is calibrated to
open at pressures above 75 psi. It should be
closed below that pressure.
 • The gerotor oil pump is driven off of the flats
on the nose of the crankshaft.
 • The pump is designed to flow the large 
volume of oil required for the 6.0LPOWER
STROKE.
 • The gerotor oil pump front cover is located
by two (2) dowel pins in the crankcase front
cover, and is sealed by a press in place 
gasket.
 • The outer housing for the oil pump is
designed into the crankcase front cover.
O-RINGO-RING
UPPER OIL PAN UPPER OIL PAN OIL PICK-UP TUBEOIL PICK-UP TUBE
OIL PUMPOIL PUMP
OIL PRESSURE REGULATOR
REGULATOR HOUSING
DOWELDOWEL
DOWELDOWEL
OUTER GEAROUTER GEAR
INNER GEARINNER GEARCRANKSHAFTCRANKSHAFT 
						

							42
43
44
Oil Cooler Housing & Filter Base Oil Cooler
Front Cover
LUBRICATION SYSTEM
24
 • Oil flows from the crankcase to the oil pump
via a passage in the back of the front cover.
 • When the oil pump is turned by the 
crankshaft it creates oil pressure and 
pushes oil through one of two passages.
One passage is to the oil cooler and the
other is through the oil pressure regulator
back to the oil pump inlet.
 • All of the passages from the front cover to
the crankcase are sealed with a silicon in
metal, one piece gasket.
 • The oil cooler is mounted in the valley of the
engine and uses engine coolant to dissipate
heat from the engine oil.
 • Oil passes from the rear of the cooler to the
front, while coolant passes from the front of
the cooler to the rear.
 • The coolant and oil are separated by 
multiple plates that create passages in the
oil cooler.
 •Note: If the oil cooler is damaged it could
cause contamination of the lubrication
and cooling systems.
 • The oil cooler housing has passages in it to
direct the flow of coolant and oil.
 • Oil is routed from the front of the crankcase
to the back of the housing where it enters
the oil cooler. The oil passes from the rear of
the oil cooler to the front of the cooler and is
cooled in the process. The oil is then sent to
the oil filter through the oil filter base.
Filtered oil is sent to the oil reservoir for the
high pressure pump and the oil passages in
the crankcase.
 • The coolant is directed from the front of the
crankcase to the front of the oil cooler. It
then passes through the oil cooler and cools
the oil. As the coolant exits the rear of the oil
cooler it is directed to the EGR cooler.
RETURN TO OIL PUMP RETURN TO OIL PUMPOIL FLOW TO OIL COOLEROIL FLOW TO OIL COOLER
ONE PIECE GASKETONE PIECE GASKET
OIL PRESSURE 
TEST PORT
OIL COOLER OIL COOLER
TO RESERVOIR & CRANKCASE
COOLANT FROM WATER PUMP
COOLANT TO
OIL COOLER OIL TO
OIL COOLER OIL FROM
OIL PUMP
COOLANT FROM
OIL COOLER OIL TO
OIL FILTER 
						

							45
46
47
Oil Reservoir & Screen Oil Filter Oil Filter Base & Valves
LUBRICATION SYSTEM
25
 • The oil reservoir for the high pressure oil
pump is located under the oil cooler in the
valley of the engine.
 • The oil reservoir holds about 1qt of oil.
 • A screen in the oil reservoir catches any
large debris that may be in the oil before it
gets to the high pressure oil pump.  • The 6.0LPOWER STROKEuses a cartridge
style oil filter, located on the top of the
engine.
 • When the oil filter is removed, the oil filter
housing drain valve is automatically opened
to drain most of the oil from the housing.
 • The oil filter element snaps into the oil filter
lid.
 • Note: The oil filter lid should be removed
before draining the oil from the oil pan so
that the oil can drain from the filter 
housing into the oil pan.  • The oil filter base routes oil to the oil filter,
engine oil pressure switch (EOP), engine oil
temperature sensor (EOT), and the 
turbocharger oil feed.
 • The oil filter base also houses the anti-drain-
back check valve that keeps oil in the oil 
filter assembly after the engine is shut off.
 • The oil cooler bypass is in the filter base and
opens at a pressure differential of 25 psi.
 • The oil filter bypass is in the oil filter stand
pipe and opens at a pressure differential of
20 psi.
 • There is an oil drain for the filter housing to
drain oil from the housing during an oil
change.
OIL TEMPERATURE SENSOR
OIL PRESSURE SWITCHOIL PRESSURE SWITCH
OIL COOLER BYPASS ANTI DRAIN BACKOIL FILTER DRAIN OIL FILTER BYPASSOIL FILTER BYPASS
OIL FILTER ELEMENT
OIL RESERVOIR SCREEN
OIL RESERVOIR SCREEN 
						

							48
49
50
 • The VGT uses oil to control the turbocharger
and to lubricate the bearings.
 • After oil passes through the turbocharger
center section, it is sent back to the
crankcase via a turbo oil drain tube.
 • The turbo oil drain tube is located under the
turbocharger and is sealed with two (2) 
o-rings, one fits into the turbocharger and
the other goes to the high pressure oil pump
cover.
Turbocharger Oil Drain Tube Turbocharger Oil Supply & VGT
Control Oil Flow at Oil Reservoir
LUBRICATION SYSTEM
26
 • There are five (5) oil passages and one
coolant passage near the oil reservoir in the
crankcase.
 • Two (2) of the oil passages are for oil feed to
the crankcase for lubrication.
 • One (1) is for oil feed to the oil cooler and
the other oil passage is oil filter drain to the
oil pan.
 • The passage in the bottom of the reservoir is
for oil feed to the high pressure oil pump.
 • The coolant passage is for coolant feed from
the water pump to the oil cooler.
 • Oil is supplied to the turbocharger from the
oil filter base via a flexible steel braided oil
line to the top of the turbocharger.
 • The oil line is connected to the oil filter base
using a snap to connect fitting and requires
a special tool for removal.
 • This line is also the feed to the VGT control
valve.
PRESSURE PUMPPRESSURE PUMP OIL FEED TO HIGHOIL FEED TO HIGH
OIL FILTER DRAIN TO PAN
OIL COOLER OIL FEED TO
OIL COOLER OIL FEED TO
BANK TAPPETTO LEFT
GALLERY BANK TAPPETTO LEFT
GALLERY
COOLANTGALLERY
FEED TO OIL
COOLERCOOLANT
FEED TO OIL
COOLERBANK TAPPET TO RIGHT
GALLERY BANK TAPPET TO RIGHT
FRONT OF ENGINEFRONT OF ENGINE
OIL SUPPLY
OIL SUPPLY
VGT CONTROL VALVEVGT CONTROL VALVE
HIGH PRESSURE PUMP COVER
HIGH PRESSURE PUMP COVER
DRAIN TUBE O-RINGS
DRAIN TUBE O-RINGS 
						

							 • The fuel supply system uses a new
Horizontal Fuel Conditioning Module
(HFCM). The HFCM filters fuel, separates
water, senses water, heats fuel, and 
recirculates warm fuel through the pump
during cool fuel conditions.
 • The 6.0LPower Strokealso has a secondary
fuel filter.
 • There is a check valve in the front of each
cylinder head that does not allow fuel to
return to the fuel supply system. This type of
system is called a dead-end fuel system.
Fuel Supply System Features
FUEL SUPPLY SYSTEM
52
Engine Fuel System Flow
27
Fuel Supply System Features
 • Horizontal Fuel Conditioning Module
(HFCM)
 • Secondary Fuel Filter
 • Fuel Check Valves
51
FUEL SUPPLY TO HEADS
FUEL RETURN
TO TANK FUEL SUPPLY
FROM PUMP
FUEL CHECK VALVESFUEL FILTER 
						

							53
FUEL SUPPLY SYSTEM
28
Engine Fuel Flow • After the fuel is conditioned by the
HFCM, the clean pressurized fuel is
sent to the secondary fuel filter
assembly where particles larger
than 4 micron are filtered out of the
fuel.
 • The secondary filter assembly also
regulates fuel pressure by releasing
excess pressure via a return fuel
line back to the HFCM.
 • It also has an orifice at the top of
the housing in order to bleed air out
of the housing and back to the fuel
tank.
 • After the fuel flows through the 
secondary filter it is directed to the
two (2) cylinder heads via fuel linespast the fuel check valves.
 • The fuel is directed to the injectors
via passages that are drilled into
the cylinder heads.
 • Once the fuel has entered the head
past the check valve, it does not
return to the fuel supply system.
This is called a dead-end fuel 
system.  • The fuel pump, located in the
Horizontal Fuel Conditioning
Module (HFCM), draws fuel from
the fuel tank and through a 10
micron fuel filter.
 • The HFCM contains the fuel pump,
filter, water separator, water in fuel
switch, fuel drain, fuel heater, and
diesel thermo recirculation valve
(DTRM).
 • The DTRM controls the flow of fuel
returned from the secondary filter
through the HFCM. If the fuel being
drawn from the fuel tank is cool
then return fuel is recirculated into
the pump, if it is warm then return
fuel is sent to the fuel tank 
						

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55
 • Fuel is drawn into the HFCM from the fuel
tank via a supply line.
 • If the temperature of the the fuel is below
50°F (10°C) it is heated by the fuel heater.
The fuel heater shuts off at 80°F (27°C).
 • After being heated, fuel enters the filter
housing via a one-way check valve.
 • Once in the filter housing, water is separated
from the fuel. If large amounts of water are
found in the fuel, a sensor in the separator
warns the operator of this condition by 
illuminating a light on the dash.
 • Fuel is then drawn through the 10 micron
fuel filter and into the fuel pump.
 • Conditioned pressurized fuel is then supplied
to the engine mounted fuel filter via a fuel
supply line. The pump has an internal 
regulator that limits fuel pressure to 100psi.
 • Fuel returning from the pressure regulator on
the engine mounted fuel filter comes into the
HFCM and a DTRM either allows the fuel to
return to the tank or returns it to the 
unfiltered side of the fuel filter in the HFCM.
The DTRM starts to open (recirculating fuel
back into the pump) at 80°F (27°C) and is
fully open at 50°F (10°C).  • The HFCM is mounted to the frame rail on
the drivers side.
 • The HFCM is a single module that performs
multiple tasks. It heats fuel, separates water
from the fuel, senses when water is present
in the fuel, filters particulates from the fuel,
creates fuel pressure needed to to supply
fuel to the engine mounted fuel filter
 • A DTRM (Diesel Thermo Recirculation
Module) is also part of the HFCM. It 
recirculates fuel that returns from the engine
mounted fuel filter back into the fuel filter
instead of back to the tank, which in cool
fuel conditions.
HFCM (Horizontal Fuel Conditioning
Module) Fuel Flow HFCM (Horizontal Fuel Conditioning
Module)
FUEL SUPPLY SYSTEM
29
56
WATER IN FUEL
WATER IN FUEL
FUEL PUMP POWER
FUEL PUMP POWER
FUEL SUPPLY TO HFCM
FUEL SUPPLY TO HFCM FUEL RETURN TO TANK
FUEL RETURN TO TANK
FUEL RETURN TO HFCM
FUEL RETURN TO HFCM
FUEL HEATER
FUEL HEATERFUEL SUPPLY TO ENGINE
FUEL SUPPLY TO ENGINE
DTRM WIF SENSOR
WIF SENSORFUEL HEATER
FUEL PUMP
FUEL FILTER
THROUGH FILTER INTO PUMP