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 way connector is located in the rear
left hand corner of the engine compartment.  • If you have no (0 psi) ICP pressure during
crank it could be the result of: major high
pressure oil leak, lack of oil supply to the
high pressure pump, bad high pressure
pump, or the gear on the high pressure
pump is loose. Use PC/ED ICP diagnostics
to determine root cause.
 • If ICP during crank is between 200-300 psi
and does not change as IPR duty cycle
increases, the IPR valve may not be 
receiving V-power or a ground signal from
the PCM. If V-power and PCM signal are
present then the IPR may be at fault. Use
PC/ED IPR Diagnostics to determine root
cause.
Injector I/O Test Power or Ground Issues
ICP Pressure Low During Crank
GENERAL DIAGNOSTICS
80
IPR IPR
12 WAY CONNECTOR 12 WAY CONNECTOR 
						

							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 will be hot and under 
pressure.  • The relative compression test is now 
available for the 6.0LPower Stroke.
 •The relative compression test measures
engine RPM during each compression
stroke while cranking the engine. It then
compares the RPM of all of the cylinders to
determine if there is a cylinder that is 
weaker than the rest.
 • Once a cylinder is determined to be weak a
manual compression test should be run on
that cylinder and a good cylinder to verify
results.  • The cylinder balance test is now available for
the 6.0LPower Stroke.
 • The cylinder balance test measures the
increase of engine RPM during each firing
cycle. It then compares the RPM of all 
cylinders to determine a weak cylinder.
 • Further testing should be done to verify the
weak cylinder (Relative compression,
Injector disable, actual compression, etc.).
Relative Compression Test Cylinder Balance Test
GENERAL DIAGNOSTICS
81
165
#5 INJECTOR OFF
ALL INJECTORS ON
#5 GLOW PLUG
REMOVED
GOOD ENGINE
AERATED OIL NON AERATED 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 logic
power feed to the FICM.
 • To check powers and grounds to the FICM
you can bring up the following pids on the
WDS:
FICMVPWR (FICM Vehicle Power battery
voltage)
FICMMPWR (FICM Main Power or output
voltage approximately 48 volts)
FICMLPWR (FICM Logic Power battery
voltage)  • A new crankcase pressure orifice tool has
been developed for the 6.0LPower Stroke.
 •The new tool has a smaller orifice in the top
so that more accurate readings could be
taken with the 0-60” gauge on the gauge
bar.
 • When using the new tool on the 6.0LPower
Strokethe maximum reading for a good
engine is 8” of water.
Crankcase Pressure Test
GENERAL DIAGNOSTICS
82
Injector Buzz/No Buzz
FICM LOGIC FUSE FICM LOGIC FUSE 
						

							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  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Notes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 
						

							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) ..............................................50 lbf/ft 68 Nm
Coolant (block) heater ....................................................30 lbf/ft 41 Nm
Crankcase breather nuts (under valve cover) ..................62 lbf/in 7 Nm
Crankcase Plug (M16) ......................................................15 lbf/ft 20 Nm
Crankshaft position (CKP) sensor ....................................96 lbf/in 11 Nm
Cylinder head bolts (see figure A)....................................figure A figure A
EGR cooler coolant supply port cover (on oil filter base)
(M6) ..........................................................89 lbf/in 10 Nm
EGR cooler V-band clamp ................................................53 lbf/in 6 Nm
EGR cooler flange (studs) (see note 1) ............................10 lbf/ft 13 Nm
EGR cooler support (see note 1) ......................................23 lbf/ft 31 Nm
EGR valve mounting bolts ..............................................10 lbf/ft 13 Nm
Engine coolant temperature sensor (ECT) ........................106 lbf/in 12 Nm
Engine oil pressure switch (EOP) ....................................106 lbf/in 12 Nm
Exhaust manifold flange (to up pipe) (see note 2) ............20 lbf/ft 27 Nm
Exhaust manifold (see note 2) ........................................28 lbf/ft 38 Nm
Exhaust pressure (EP) sensor bracket ............................106 lbf/in 12 Nm
Exhaust pressure (EP) sensor ..........................................106 lbf/in 12 Nm
Exhaust pressure (EP) tube nuts (see note 2) ..................22 lbf/ft 30 Nm
Exhaust up pipe to EGR cooler (v-band) ..........................20 lbf/ft 27 Nm
Exhaust up pipe coupling on right side ............................20 lbf/ft 27 Nm
Flywheel bolts (see figure B) ..........................................69 lbf/ft 94 Nm
Front cover module bolts ................................................18 lbf/ft 24 Nm
Fuel check valve (banjo bolt) ..........................................28 lbf/ft 38 Nm
Fuel filter supply and return lines....................................32 lbf/ft 43 Nm
Fuel filter supply to head lines ........................................19 lbf/ft 26 Nm
Fuel injector hold down ..................................................24 lbf/ft 33 Nm
Fuel rail plug (rear of head) ............................................20 lbf/ft 27 Nm
Glow plug ..................................................................14 lbf/ft 19 Nm
Glow plug control module (GPCM) ..................................71 lbf/in 8 Nm
Heat shield for intake manifold (M6 nut) ..........................96 lbf/in 11 Nm
Heat shield bolts for rear (M6 thread forming) ..................96 lbf/in 11 Nm
(M10) ........................................36 lbf/ft 49 Nm
High pressure discharge tube mounting bolts ..................71 lbf/in 8 Nm
High pressure stand pipe ................................................33 lbf/ft 45 Nm
High pressure oil rail check valve ....................................25 lbf/ft 34 Nm
High pressure oil rail plug (M14)......................................33 lbf/ft 45 Nm
(M8) ......................................96 lbf/in 11 Nm
High pressure oil rail bolt (see figure C) ..........................96 lbf/in 11 Nm
High pressure pump cover bolts ......................................96 lbf/in 11 Nm
High pressure pump cover plug ......................................26 lbf/ft 35 Nm
High pressure pump drive gear bolt ................................95 lbf/ft 129 Nm
High pressure pump mounting bolts ................................18 lbf/ft 24 Nm
Injection control pressure (ICP) sensor ............................106 lbf/in 12 Nm
Injection pressure regulator (IPR) ....................................37 lbf/ft 50 Nm
Intake air temperature 2 (IAT2) sensor ............................13 lbf/ft 17 Nm
Intake manifold (see figure D) ..........................................96 lbf/in 11 Nm
Lifting eye bolts ..............................................................30 lbf/ft 41 Nm
Lower crankcase main bolts (see figure E) ......................figure A figure A
COMPONENT STANDARD METRIC 
						

							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) ........................................53 lbf/in 6 Nm
(reinstallation) ..........................27 lbf/in 3 Nm
Oil pan drain plug (see note 3) ........................................18 lbf/ft 25 Nm
Oil pickup tube flange bolts ............................................18 lbf/ft 24 Nm
Oil pump housing bolts ..................................................72 lbf/in 8 Nm
Oil pressure regulator plug..............................................19-21 lbf/ft 26-29 Nm
Piston cooling jet (see note 4) ........................................10 lbf/ft 13 Nm
Rocker arm fulcrum bolts ................................................23 lbf/ft 31 Nm
Water pump bolts (M8) ....................................................17 lbf/ft 23 Nm
Water pump plugs ..........................................................26-28 lbf/ft 35-38 Nm
Water pump pulley bolts ..................................................23 lbf/ft 31 Nm
Thermostat housing bolts ................................................17 lbf/ft 23 Nm
Turbo exhaust adapter v-band clamp ................................80 lbf/in 9 Nm
Turbo oil supply bolts ....................................................18 lbf/ft 24 Nm
Turbo oil supply snap to connect fitting ..........................8-13 lbf/ft 11-18 Nm
Turbo to mounting bracket bolts (see note 2) ..................28 lbf/ft 38 Nm
Turbo bracket to crankcase mounting bolts ......................23 lbf/ft 31 Nm
Valve cover bolts ............................................................71 lbf/in 8 Nm
Vibration damper (see note 5) (initial) ..............................50 lbf/ft 68 Nm
(Final) ..............................additional 90 degrees rotation
COMPONENT STANDARD METRIC
STANDARD TORQUE CHART
Hex Flange Head
Thread Torque Torque Wrench
Diameter lbf/ft Nm Size (mm)
M6 x 1 8 11 8
M8 x 1.25 18 24 10
M10 x 1.5 36 49 13
M12 x 1.75 61 83 15
M16 x 2 154 208 21
Hex Head
M6 x 1 6 8 10
M8 x 1.25 15 20 13
M10 x 1.5 30 40 16
M12 x 1.75 51 69 18
M16 x 2 128 173 24
Pipe Thread
1/8” NPT 7 10.2
1/4” NPT 10 13.6
3/8” NPT 15 20.4
1/2” NPT 25 34.0
3/4” NPT 30 40.8
 • All Figures on next page.Special Torque Chart Notes
 • 1) Tighten 2 M6 studs in front EGR cooler flange    
first then install M8 EGR cooler support bolt.
 • 2) Apply High Temperature Nickel Anti-Seize
Lubricant (F6AZ-9L494-AA) to threads of bolts
prior to assembly.
 • 3) Lightly coat o-ring with engine oil before
installing.
 • 4) Apply Threadlock 262 to bolt threads prior to
assembly
 • 5) Tighten bolts across center of crankshaft.
Always use new bolts in vibration damper! 
						

							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 M14 cylinder head bolts an additional 90o 
clockwise in the numerical sequence shown.
 • Step 6: Torque the M8 (11-15) cylinder head bolts to 18 lbf/ft (24 Nm) in the numerical sequence shown.
 • Final Step: Torque the M8 cylinder head bolts to 24 lbf/ft (32 Nm) in the numerical sequence shown.
 • Note: Always use new head bolts.
59
8426
731
1015 1412 11 13Intake Side
Exhaust Side
Figure A
Figure B
Flywheel Bolts
 • Step 1: Torque the bolts to 1-5 lbf/ft (1.4-7 Nm) in the numerical sequence shown above.
 • Final step: Torque the bolts to 69 lbf/ft (94 Nm) in the numerical sequence shown above.
1
5
9
4
82
6
10
3
7 
						

							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 sequence shown.
Front of Engine
12
11
10
9
420
19
17
2
35
6
17
18816
15
14 13
Bottom View
Figure E
Main Bearing Bolts
 • Step 1: Torque the bolts to 110 lbf/ft (149 Nm) in the numerical sequence shown.
 • Step 2: Torque the bolts to 130 lbf/ft (176 Nm) in the numerical sequence shown.
 • Final step: Torque the bolts to 170 lbf/ft (231 Nm) in the numerical sequence shown. 
						

							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 REMAINDER OF THE 
DIAGNOSTIC PROCEDURE.
 7. Perform KOEO On-Demand Self Test11. Glow Plug System Operation •Use scan tool. DTC's set during this test are current faultsGPCM OperationDiagnostic•Glow Plug ON time is dependent on oil temperature 1. Visual Engine/Chassis InspectionTrouble Codesand altitude. The Glow Plug Control Module (GPCM)
Fuel  Oil  Coolant  Electrical   Hoses  Leaks 8.   Retrieve Continuous Trouble Codescomes on between 1 and 120 sec., and does not come
Method Check•Use the scan tool. on at all if oil temp is above 131 F.
Visual•DTC's retrieved during this test are historical faults.•Using a scan tool , check Continuous and KOEO DTC's.DiagnosticIf codes are present go to Pinpoint Test AF. 2. Check Engine Oil Level Trouble Codes•Verify B+ voltage is being supplied to GPCM.•Check for contaminants (fuel, coolant).9.   KOEO Injector Electrical Self Test (Click Test)•Using the scan tool GPCTM and EOT pids, verify
•Correct Grade/Viscosity.•Use scan tool. Injector DTC's will be displayed at test end. glow plug "on" time .•Miles/Hours on oil ,correct level.•All injectors will momentarily click, then each injector will•Turn key to run position, measure voltage ("on"time)
Method Check(Dependent on oil temperature and altitude)
VisualInjectorRelay on time Spec. Measurement
Trouble Codes 1 to 120 B +
 3.  Intake/Exhaust Restriction »
If self test codes are retrieved, go to appropriate PPT  test.seconds•Inspect air filter and inlet ducts. 10. Scan Tool - Data List Monitoring Wait to Start Lamp "on" time is independent from g/p "on" time 
•Inspect exhaust system.•Scan tool may reset below 9.5 volts.Glow Plug Resistance•Check if air filter minder indicator has been illuminated•Select the parameters indicated from the scan tool•Disconnect the 4-pin connector at front of valve cover
Method Checkparameter list and monitor while cranking engine.•Measure each Glow Plug resistance to Bat. ground.
VisualParameter Spec. Measurement•Measure engine harness resistance to GPCM
V PWRGlow  Glow Plug Harness to 
 4.  Sufficient Clean Fuel FICMLPWR8 volt min.Plug to Ground GPCM connector•Check if the WATER IN FUEL lamp has been FICMVPWRNumber .1 to 2 ohms 0 to 1 ohms
illuminated.RPM100 RPM #1
•After verifying that there is fuel in the tank, drain a minimum #3
sample from fuel control module.ICP3.5 mPa min. #5
•Cetane rating between 40-50 is recommended for  (500 PSI) #7
optimum start.ICP volts.80 V min. #2
Method CheckFUEL PW500 uS - 2 mS #4
Visual FICMSYNCYes/No #6
 A -V PWR - If low voltage condition is present, check battery,
#8
 5.  Electric Fuel Pump Pressurecharging system, or power/gnd circuits to the PCM.•Verify that the fuel pump has voltage and gnd. At key on. B -FICMLPWR - No/low voltage indicated could be caused•Measure fuel pressure at engine fuel filter housing test by 12-way connector issue or logic power fuse.
port with a (0-160 PSI) gauge at key on.Refer to Pinpoint S for detailed 12-way conn. diagnosticsFuel pump runs for 20 sec. at key on and pressure C -FICMVPWR - No or low voltage indicated could be caused
falls after key off.by 12-way connector issues.
Instrument Spec. Measurement D -RPM - Low RPM can be caused by starting/charging
0-160 PSI 45 PSI min. system issues. No RPM indicated while cranking could be 
GaugeCMP or CKP faults.
If pressure fails low go to next step to verify no restriction E -ICP - A minimum of 500 PSI (3.5 mPa) is required for 6. Electric Fuel Pump Inlet Restrictionthe injectors to be enabled.  No or low oil in the system,•Measure restriction at fuel pump inlet. system leakage, injector O-Rings, faulty IPR, or high
Instrument Spec. Measurementpressure pump could cause low pressure.•Add 5 seconds to glow plug on time when above
0-30 " Hg6" Hg MAXIPR duty cycle defaults to 14 % (300 PSI) w/o CKP signal.7000 feet in altitude, but not to exceed 120 seconds.
vacuum   F -ICP V - Voltage reading below spec indicates low ICP
»
If > 6" Hg restriction, check lines between pump and fuel tank.during crank.»
If < 6" Hg, inspect both fuel filters. If filters are OK, check fuel G -FUEL PW - Pulse width defaults to 0 w/o CKP signal regulator. If regulator and filters are OK, replace fuel pump. H -FICMSYNC- No sync could be caused CMP or CKP faults.»Refer to PC/ED section 4 for detailed test procedures.
click in sequence 1-8. Sequence repeats three times.
0 20 40 60 80 100 120 140
0 20 40 60 80 100 120 140
EOT (°F)
Time (seconds)
 NOTE: A hard start/ No start concern with EOT 
Temp. below 60F perform step 10 first. 
						

							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 OF THE 
DIAGNOSTIC PROCEDURE.
 1. Visual Engine/Chassis Inspection  8.  EGR Position 12a. Low Idle Stability (ICP Pressure)•Verify that there are no fluid or pressure leaks.•Perform with key on, engine off.•Check at low idle, EOT above 70° C (170° F)•Inspect all wire connections for damage.•Use scan tool to command Output State Control for EGR.•Monitor ICP and RPM with scan tool.•Inspect MAP hose,intercooler hose,and manifolds for leaks.•Monitor EGR position sensor PID and calculate travel..Parameter Spec. @ 670 RPM Measurement
Fuel  Oil  Coolant  Electrical   Hoses  LeaksInstrument Spec. Percent Actual PercentICP4.5-5.5 Mpa + .3MPaMethod CheckScan tool0% (0.6-1.2 V)(650-800 PSI + 45 PSI)VisualClosed   _______ Closed Take reading before disconnecting ICPIf engine RPM is unstable, disconnect ICP sensor (ICP will default). 2.  Sufficient Clean Fuel 90 % - 100% »If RPM is still unstable, re-connect sensor and go to 12b.
•Check if WATER IN FUEL indicator has been illuminated. (4.0-4.52 V)   _______ Open»If RPM smoothes out, the ICP sensor is at fault.
•
Drain sample from fuel control module housing. Open12b. Injection Pressure Regulator Test•Cetane rating between 40-50 is recommended for •Check at low idle, EOT above 70° C (170° F)
optimum performance 90 % and 3.2 V    _______ Travel•Monitor IPR with scan tool.
TravelParameter Spec. @ 670 RPM Measurement
Method Check
»
Repair issue causing out of spec. values before continuing.IPR30 % MAXVisual9.   Exhaust Restriction »If duty cycle is below MAX spec go to next step.
•
Visually inspect exhaust system for damage»If duty cycle is above MAX spec, check for system leak with
 3. Check Engine Oil Level •Monitor EP with the scan tool with the engine temperatureprocedure in Hard Start/No Start section. Test 10c.
•
Check for contaminants (fuel, coolant). at 70° C (170° F)minimum at 3,800 RPM in park/neutral.13.  Boost Pressure Test•Correct Grade/Viscosity.Parameter Spec. Measurement•Carefully inspect intercooler tubes/connections, turbocharger•Miles/hours on oil, correct level.EP234 kPa (34 PSI)connections, and MAP hose for signs of damage or leaks.
Method CheckMAX '@ 3800 RPM •Perform boost test at 3300 RPM.
Visual 10a.  Electric Fuel Pump Pressure •Monitor MGP and RPM with scan tool.•Measure fuel pressure at engine filter housing test port.•Road Test - select appropriate gear to obtain desired engine 4. Perform KOEO On Demand Test•Road Test- engine at full load condition speed and full load on engine climbing hill or loaded truck..•Use the scan tool.Instrument Spec. Measurement•DTCs set during this test are current faults.0-1.1 Mpa310-379 kPa3300 RPM
Diagnostic(0-160 PSI) (45-55 PSI) min.Parameter Spec. PSI G Measurement
Trouble Codes Gauge MGP 22 PSIG MIN
 5. Retrieve Continuous DTC's»
If fuel pressure fails low, Go to step10b.»If test fails low, inspect turbo blades for damage.
•Use the scan tool.»
If pressure is above spec, check fuel return lines for restriction.
•DTCs retrieved during this test are historical faults.If no restriction is present, replace fuel pressure regulator valve.14.  Crankcase Pressure Test Diagnostic 10b. Electric Fuel Pump Inlet Restriction •Measure at oil fill tube with 6.0L Crankcase Pressure Tester
Trouble Codes•Measure restriction at fuel pump inlet. p/n 303-758, with engine at 70° C (170° F) minimum. 6.   KOEO Injector Electrical Self-TestInstrument Spec. Measurement•Block breather tube on left valve cover.•Use the scan tool.0-30 " Hg6" Hg MAX•Measure at WOT with no load at 3,000 RPM.•All injectors will momentarily click, then individualvacuum Instrument Spec. Measurement
injectors will click in sequence 1 though 8.»
If > 6" Hg restriction, check lines between pump and fuel tank.(0-60" H²0) 8" H²0 MAXInjector»
If < 6" Hg, inspect both fuel filters. If filters are OK, check fuelMagnehelicTrouble Codesregulator. If regulator and filters are OK, replace fuel pump.If more than 8" H²0, refer to base engine in Shop Manual
»
If self test codes are retrieved, go to appropriate PPT. 10c. Fuel Aeration Test  15.  Oil Aeration Test  
 7.  Intake Restriction •Install clear hose on fuel return line at fuel control module.•Run engine at 3000 RPM for 1 minute.•Check filter minder switch/indicator.Refer to shop manual for approved procedure.•Take oil sample from the Oil Pressure Switch port at idle.•Measure vacuum on clean side of  air inlet system•Run at WOT for 2 min. Return fuel should be free of bubbles.•Inspect sample for presence of air bubbles.
at WOT with magnehelic gauge.Method Check Method Check
Instrument Spec. CheckVisual Visual
Magnehelic/
»
If air is present in return fuel, inspect fuel system for leaks.Filter Minder2"-25" H²0 11.  Perform KOER  On Demand Test»Excessive oil aeration can be caused by depleated oil additives,
•This will test the ICP, EGR and VGT performance.pick-up tube leak, front cover seal leak, or upper pan seal leak.KOERNote: If performance concern still exists, refer to Enhanced Injector DTCDiagnostics in this section.