6.0L HARD START / LONG CRANK / NO START TSB LOW INJECTOR CONTROL PRESSURE (ICP)

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1 6.0L HARD START / LONG CRANK / NO START TSB LOW INJECTOR CONTROL PRESSURE (ICP) FORD: 2005 Excursion F-Super Duty E-350, E-450 This article supersedes TSBs and to update the Service Procedure and Service Labor Times. ISSUE Some F-Super Duty, E-Series and 2005 Excursion vehicles equipped with a 6.0L diesel engine may exhibit a hard start / long crank or no start condition due to low injection control pressure (ICP). ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE A FLOW CHART OF THIS PROCEDURE CAN BE FOUND AT THE END OF THIS ARTICLE. (FIGURES 13-16) b. If DTCs P2290 and/or P2291 are present proceed to the ICP Graph Comparison Test. c. If DTCs other than P2623, P2290 and/or P2291 are present refer to PC/ED, and do not continue with this procedure. d. If no DTCs are present proceed to the ICP Graph Comparison Test. ICP Graph Comparison Test BATTERIES MUST BE FULLY CHARGED BEFORE PROCEEDING. If oil is leaking from the ICP system or if air is trapped in the ICP system, the injection pressure regulator (IPR) valve may be commanded fully closed by the Powertrain control module (PCM) while the starter is engaged in an attempt to exceed 500 psi (3.5 MPa). 1. Select the parameters indicated from the scan THE LOW PRESSURE OIL SYSTEM MUST BE tool parameter list. WORKING PROPERLY IN ORDER FOR THE HIGH PRESSURE OIL SYSTEM TO BUILD ICP a. ICP Pressure + Voltage. PRESSURE. THIS INCLUDES ADEQUATE BASE ENGINE OIL SUPPLY PRESSURE AND GOOD b. IPR Duty Cycle. QUALITY PROPERLY MAINTAINED OIL. THIS c. Engine Speed (RPM). MUST BE VALIDATED BEFORE CONTINUING WITH THIS PROCEDURE. 2. ICP pressure should reach 500 psi (3.5 MPa) within five (5) seconds of cranking engine. 1. Install the Integrated Diagnostic System (IDS) Normal crank time is 3-5 seconds. scan tool, check ICP voltage key on engine off (KOEO) for bias: If voltage is not between 0.15 a. Normal start response for ICP, IPR Duty V and 0.35 V refer to Powertrain Cycle and Engine Speed - Operation shown. Controls/Emissions Diagnosis (PC/ED), and do not continue with this procedure. (Figure 1) 2. Check for diagnostic trouble codes (DTCs). a. If DTC P2623 is present go to pinpoint test R in PC/ED before continuing to the ICP Graph Comparison Test. : The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by do-it-yourselfers. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.the information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates.the most recent information is available through Ford Motor Company s on-line technical resources. Copyright 2008 Ford Motor Company Online Publication Date August 28, 2008 PAGE 1

2 Figure 1 - Article b. Hard start response for ICP, IPR Duty Cycle and Engine Speed - Operation shown. (Figure 2) Figure 2 - Article c. No start response for ICP, IPR Duty Cycle and Engine Speed - Operation shown. (Figure 3) PAGE 2

3 Figure 3 - Article Compare the ICP PID data to the graph. d. If engine does not start, proceed to Air (Figure 1) Pressure test ICP. a. If the ICP PID data is within specification, 5. Does the engine start? (Figure 1), and the engine will not start, refer to PC/ED for no start diagnosis, and a. If the engine starts and the IPR has been do not continue with this procedure. replaced proceed to Step 7. b. If the ICP PID data is within specification, (Figure 2 ) and the engine starts, drive the vehicle and monitor the engine oil temperature using IDS until the engine oil temperature (EOT) reaches 195 F (91 C). Proceed to Step 4. b. If the IPR has not been replaced drive the vehicle and monitor the engine oil temperature using IDS until the EOT reaches 195 F (91 C). Turn off engine and proceed to Step 6. c. If the engine will not start, proceed to the c. If the ICP PID data is not within Air Pressure Test (ICP) procedure. Refer to specifications, (Figures 2 or 3), proceed to appropriate vehicle. Step If the engine starts with EOT at 195 F (91 C) perform a run up test by a slow neutral run up 4. With engine oil temperature (EOT) at 195 F (91 C). Crank the engine and recheck the ICP PID data. a. If repairs were performed and the ICP PID data is within specification, (Figure. 1), release the vehicle to the customer. in park/neutral. Does the engine run rough between 3000 and 4000 RPM? a. If the engine runs rough replace the IPR valve. Proceed to Step 7. b. If the engine does not run rough, proceed to the Air Pressure Test (ICP) procedure. b. If no repair has been made and the ICP PID data is within specification, (Figure. 1), c. If the engine does not start, proceed to the refer to the PC/ED for intermittent diagnosis, Air Pressure Test (ICP) procedure. and do not continue with this procedure. 7. Start the engine and perform a run up test by a c. If the ICP PID data is not within slow neutral run up in park/neutral. Does the specification and engine starts, (Figures 2 or engine run rough between 3000 and ), proceed to Step 6. RPM? PAGE 3

4 a. If the engine runs rough proceed to the Air Pressure Test (ICP) procedure. b. If the engine does not run rough crank the engine and recheck the ICP PID data. (1) If the ICP PID data is within specification, (Figure 1), release the vehicle to the customer. (2) If the ICP PID data is not within specification, (Figure 1), proceed to the Air Pressure Test (ICP) procedure. Air Pressure Test ICP Figure 4 - Article BEFORE PERFORMING THIS TEST, INSPECT 3. Install test adapter in the top of the THE O-RINGS OF THE TEST TOOLS. REPLACE high-pressure oil pump. Attach shop air hose to IF WORN, CRACKED OR CUT. the test adapter. (Figure 4) 4. Apply shop air at 100 psi (689 kpa) maximum THE AIR PRESSURE APPLIED FOR THIS TEST to the high-pressure oil pump. MUST BE 100 PSI (689 kpa). WHEN AIR PRESSURE IS APPLIED FOR THE FIRST TIME, 5. Using IDS, command IPR open for two (2) IT MAY TAKE 3 TO 5 MINUTES BEFORE THE minutes to clear the oil from the high pressure LEAK CAN BE HEARD. THIS ALLOWS THE AIR oil system. PRESSURE TO DISPLACE THE ENGINE OIL IN 6. Using IDS close the IPR valve by increasing THE ICP SYSTEM. ONCE THE ENGINE OIL IS the IPR duty cycle. If no air noise change is DISPLACED, AN AIR LEAK CAN BE HEARD heard, the IPR valve may not be functioning as ALMOST IMMEDIATELY AFTER APPLYING AIR commanded. If the IPR has been replaced PRESSURE. proceed to Step 9. If the IPR has not been CAUTION replaced in a previous repair install a new IPR DO NOT LEAVE THE IPR VALVE ENERGIZED valve and perform a slow neutral run up in LONGER THAN 120 SECONDS. THIS CAN park/neutral. DAMAGE THE IPR VALVE Econoline a. If the engine will not start repeat the Air Pressure Test (ICP) procedure. 1. Remove the engine cover; refer to Work Shop Manual (WSM), Section Remove M 12 plug from the top of the high-pressure oil pump. (Figure 4) b. If the engine runs rough between 3000 and 4000 RPM repeat the Air Pressure Test (ICP) procedure. c. If engine does not run rough between 3000 and 4000 RPM, Crank the engine and recheck the ICP graph comparison test. 7. If the ICP PID data is not within specification, (Figure 1), proceed to the Air Pressure Test (ICP) procedure. If the ICP PID data is within specification, (Figure 1), start and drive the vehicle, monitor the engine oil temperature using IDS until the EOT reaches 195 F (91 C). 8. With EOT at 195 F (91 C), crank the engine and recheck the ICP graph comparison test. PAGE 4

5 a. If repairs were performed and if the ICP PID data is within specification, (Figure 1), A PIECE OF HOSE THAT WILL FIT DOWN INTO release the vehicle to the customer. THE OIL FILL STAND TUBE MAY BE NEEDED TO AID IN DETECTING AIR LEAKS IN THE b. If the ICP PID data is not within FOLLOWING TESTS. THE AIR PRESSURE specification, (Figure 1), repeat the Air APPLIED FOR THIS TEST MUST BE 689 KPA Pressure Test (ICP) procedure in this article. (100 PSI). WHEN AIR PRESSURE IS APPLIED 9. Listen for an air leak. If a no start or hard start FOR THE FIRST TIME, IT MAY TAKE 3 TO 5 condition exists, an audible leak may be MINUTES BEFORE THE LEAK CAN BE HEARD. identified by using a stethoscope through the oil THIS ALLOWS THE AIR PRESSURE TO fill tube or left valve cover crankcase vent hole DISPLACE THE ENGINE OIL IN THE ICP or by listening at the rear of the engine. SYSTEM. ONCE THE ENGINE OIL IS DISPLACED, AN AIR LEAK CAN BE HEARD 10. If the leak is isolated to the back of the engine, ALMOST IMMEDIATELY AFTER APPLYING AIR go to Replace Snap To Connect (STC) PRESSURE. procedure. 3. Connect the shop air supply line to the ICP 11. If a leak is detected under a valve cover, system test adaptor and apply 100 psi (689 perform the Under Valve Cover Air Leak Test kpa) of air pressure. (Figure 6) procedure. 12. If no audible air leaks are detected, go to High Pressure Oil Pump Test procedure. F-Super Duty And Excursion 1. Remove the ICP sensor from the right side valve cover. Refer to WSM, Section C. Install the ICP system test adaptor in the threaded cavity where the ICP sensor was located. (Figure 5) Figure 6 - Article AN AIR LEAK SHOULD BE HEARD AT THIS TIME. AIR SHOULD BE PASSING THROUGH THE IPR VALVE AND RETURNING TO THE CRANKCASE WHEN THE IPR VALVE IS NOT ENERGIZED. Figure 5 - Article Remove the oil fill cap from the valve cover. 4. Using IDS, command IPR open for two (2) minutes to clear the oil from the high pressure oil system. 5. Using IDS, close the IPR valve by increasing the IPR duty cycle. a. If no air noise change is heard, the IPR valve may not be functioning as commanded. b. If the IPR has been replaced proceed to Step 8. PAGE 5

6 c. If the IPR has not been replaced in a 1. Remove the high-pressure oil pump per WSM, previous repair install a new IPR valve and Section C. perform a slow neutral run up in park/neutral. DO NOT REMOVE THE BRANCH TUBE (1) If the engine will not start repeat the ASSEMBLY OR REAR COVER. Air Pressure Test (ICP) procedure. 2. Mount the high pressure oil pump securely in a (2) If the engine runs rough between 3000 vise. and 4000 RPM repeat the Air Pressure Test (ICP) procedure. IF THE HIGH-PRESSURE OIL PUMP AND (3) If engine does not run rough between BRANCH TUBE ADAPTER HAS AN ASSEMBLY 3000 and 4000 RPM, crank the engine SUPPORT BRACKET, REMOVE AND DISCARD and recheck the ICP comparison test. THE ASSEMBLY SUPPORT, AND ALL 6. ATTACHING HARDWARE. THIS WILL NOT BE If the ICP PID data is not within specification, REUSED. (Figure 1), proceed to the Air Pressure Test (ICP) procedure. If the ICP PID data is within 3. Remove (unthread) the existing branch tube specification, (Figure 1), start and drive the adapter and STC or jam nut fitting from the vehicle, monitor the engine oil temperature high-pressure oil pump. Discard either type of using IDS until the engine oil temperature branch tube adapters. (EOT) reaches 195 F (91 C) 4. Remove the dowel pin. (Figure 7) 7. With engine oil temperature (EOT) at 195 F (91 C), crank the engine and recheck the ICP PID data. a. If repairs were performed and if the ICP PID data is within specification, (Figure 1), release the vehicle to the customer. b. If the ICP PID data is not within specification, (Figure 1), repeat the Air Pressure Test (ICP) procedure in this article. 8. Listen for an air leak. If a no start or hard start condition exists, an audible leak may be identified by using a stethoscope through the oil fill tube or left valve cover crankcase vent hole or by listening at the rear of the engine. Figure 7 - Article If the leak is isolated to the back of the engine, proceed to replace STC procedure. IT IS NOT NECESSARY TO REPLACE THE HIGH PRESSURE PUMP WHEN REPLACING THE 10. If a leak is detected under a valve cover, go to QUICK CONNECT FITTINGS. Under Valve Cover Air Leak Test procedure. CAUTION 11. If no audible air leaks are detected, proceed to TO PREVENT ENGINE DAMAGE, MATCH NEW High Pressure Oil Pump Test procedure. O-RINGS WITH THE O-RINGS REMOVED. SEVERAL O-RINGS ARE SIMILAR IN SIZE, BUT Replace STC WILL NOT SEAL IF USED IN THE WRONG LOCATION. AN AIR LEAK ON THE HIGH PRESSURE OIL 5. Prior to installing the new jam nut fitting, PUMP SHAFT LIP SEAL IS NORMAL. THIS IS lubricate the entire jam nut fitting with clean NOT AN INDICATION OF A HIGH PRESSURE OIL engine oil, rotate the jam nut clockwise to the LEAK AND THE HIGH PRESSURE OIL PUMP base of the branch tube adapter. The adapter SHOULD NOT BE REPLACED FOR THIS is threaded to the jam nut. (Figure 8) CONDITION. PAGE 6

7 Figure 8 - Article Figure 10 - Article CAUTION THE BRANCH TUBE ADAPTER MUST BE INSTALLED AT THE CORRECT DEPTH TO PREVENT HIGH PRESSURE OIL LEAKS. 6. Install the branch tube adapter into the high-pressure oil pump by threading it five (5) complete turns to set proper depth and set proper orientation. Tighten the jam nut to seat the O-ring at this time. (Figure 9) Figure 9 - Article CAUTION TO PREVENT ENGINE DAMAGE, BRANCH TUBE ADAPTER OIL OUTLET HOLE MUST FACE DOWN. Figure 11 - Article With plastic holding tool securely fastened, torque jam nut to 49 lb-ft (66 N m) with a 15/16 crow foot open end wrench and torque wrench. TORQUE SPECIFICATION FOR STEP 8 IS CALCULATED FOR THE USE OF A CROW FOOT OPEN END WRENCH. 9. Remove and discard holding tool, plastic bolts and wing nuts. 10. Install the new dowel pin provided in kit. 11. Lubricate and install a new O-ring in the branch tube inlet recess and in the high-pressure oil pump inlet recess. 7. Loosen the jam nut 1/4 turn. Install holding tool using the supplied plastic bolts and wing nuts CAUTION to align and position the jam nut fitting. (Figures TO PREVENT ENGINE DAMAGE THE OIL 10 and 11) SUPPLY HOLE IN THE BRANCH TUBE ADAPTER MUST FACE THE BRANCH TUBE ASSEMBLY. PAGE 7

8 12. Install the high-pressure oil pump with branch tube adapter already installed. Use new bolts BEFORE PERFORMING TEST PLACE THE supplied in kit. Finger tighten the three (3) M TURBOCHARGER OIL FEED TUBE INTO A 8x45 bolts securing the high-pressure oil pump SUITABLE CONTAINER TO CATCH THE ENGINE to the crankcase and the two (2) M 6x30 bolts OIL. holding the branch tube adapter to the branch tube. 3. Disconnect the fuel injector control module (FICM) relay. NOTICE BRANCH TUBE ADAPTER TO BRANCH 4. Crank the engine to prime the oil system. TUBE HOLE MISALIGNMENT IN MOST CASES THERE IS ENOUGH CLEARANCE IN THE 5. Repeat Air Pressure Test (ICP). BRANCH TUBE ASSEMBLY AND a. If no leaks are found, reconnect the FICM HIGH-PRESSURE OIL PUMP ASSEMBLY FOR relay, check engine oil level, and refill as PROPER HOLE ALIGNMENT. IF UNABLE, TO required. Return to customer. ALIGN HOLES THE BRANCH TUBE ASSEMBLY WILL HAVE TO BE REPLACED. (FIGURE 12) b. If leaks are found, proceed to Step Remove and discard M 12 plug from the top of the high-pressure oil pump. (Figure 4) 7. Install ICP system test adaptor in the top of the high-pressure oil pump. Attach shop air hose to the test adaptor. (Figure 5) 8. Apply shop air at 100 psi (689 kpa) maximum to the high-pressure oil pump. 9. Using IDS command IPR closed. 10. Listen for air leak. 11. If no leak is found, remove the test adapter and install the new M 12 plug provided in service Figure 12 - Article kit. Tighten M 12 plug to 26 lb-ft (36 N m). Reassemble the vehicle, check engine oil level, 13. Tighten three (3) M 8x45 bolts securing the and refill as required. Return to customer. high-pressure oil pump to the crankcase to 23 lb-ft (31 N m) 12. If a leak is identified in the branch tube, use the Branch Tube Replacement Procedure for 14. Tighten two (2) M 6x30 bolts that hold the F-Super Duty and Excursion. Econoline refer to branch tube adapter jam nut to branch tube to WSM, Section C. 97 lb-in (11 N m). Pressure test to verify repair and go to Air Pressure Testing (Pump). After 13. If a leak is identified under the valve covers, STC replacement to verify no other leaks are remove the test adapter and install the new M present. 12 plug provided in service kit. Tighten M 12 plug to 26 lb-ft (36 N m) and go to Under Valve Air Pressure Testing (Pump) - After STC Cover Leak Test procedure. Replacement 1. High Pressure Oil Pump Test - No Audible Air Remove the ICP adapter from the ICP Leak port, install the ICP sensor, Tighten to 9 lb-ft (12 N m) if it was removed. 1. Remove the left and right hand valve covers. 2. Install IPR valve. Refer to WSM, Section Remove both upper crankcase to head tubes (stand pipes). PAGE 8

9 3. Install the fuel rail block off tool /2, Under Valve Cover Leak Test (Air Leak into the rear of the left high pressure oil rail Detected) where the upper stand pipe was removed. 4. Remove the ICP sensor. BEFORE PERFORMING THIS TEST, INSPECT 5. THE O-RINGS OF THE TEST TOOLS. REPLACE Install the ICP sensor into the block off tool IF WORN, CRACKED OR CUT /1 into the rear of the right high pressure oil rail where the upper stand pipe 1. If not removed previously, remove the left and was removed. right hand valve covers. Refer to WSM, Section 6. Install jumper harness 418-D003 (D94T-50-A) to the existing ICP sensor connector. If the jumper 2. Remove the ICP sensor from the right side high harness is unavailable, proceed to Alternate pressure oil rail and install the ICP system test High Pressure Oil Pump Output Test procedure. adaptor in the threaded cavity where 7. Disconnect the FICM relay. the ICP sensor was located Apply 100 psi (689 KPa) regulated shop air Crank the engine while monitoring the ICP PID, pressure. Pressure should reach a peak of a minimum 1500 psi (10.5 MPa). 4. Key on, engine off. Using the scan tool, 9. command the IPR valve closed by increasing If a peak of a minimum of 1500 psi (10.5 MPa) the IPR duty cycle. is not reached, replace the high pressure pump. 5. Listen for air leaks around the fuel injectors, 10. If pressure is OK, proceed to Under Valve D-rings and fuel rail plugs at both high pressure Cover Leak Test procedure. oil rails. If leaks are found repair as necessary. Alternate High Pressure Oil Pump Output Test - If Jumper Harness 418-D003 (D94T-50-A) Unavailable BEFORE PERFORMING THIS TEST, INSPECT THE O-RINGS OF THE TEST TOOLS. REPLACE IF WORN, CRACKED OR CUT. 1. Remove the left and right hand valve covers. Refer to WSM, Section Remove the left upper crankcase to head tube (stand pipe) and install the oil rail block off tool /2 into the rear of the left high pressure oil rail. 3. Install the ICP sensor and connect. 4. Disconnect the FICM relay. 5. Crank the engine while monitoring ICP PID. Pressure should reach a peak of a minimum of 1500 psi (10.5 MPa). 6. If a peak of a minimum of 1500 psi (10.5 MPa) is not reached, replace the high pressure pump. 7. If pressure is OK, go to Under Valve Cover Leak Test procedure. Branch Tube Replacement For F-Super Duty And Excursion Vehicles Only 1. Remove the transmission, see the appropriate model year WSM, Section LEAVE THE FLYWHEEL ON, IT WILL MAKE IT EASIER TO TURN THE ENGINE OVER TO TOP DEAD CENTER (TDC), THE TRANSMISSION FLUID DOES NOT NEED TO BE DRAINED. 2. Set engine at TDC (both cylinder number 1 rocker arms should be loose) (See rocker arm removal procedure in the appropriate online WSM, Section C). 3. Remove the right and left side high-pressure oil rails. 4. Remove and inspect both high-pressure standpipes for D-ring wear or stand pipe damage. If damaged replace stand pipe(s). 5. Remove the port plugs and inspect for damage, if damaged replace the port plugs. Refer to (Figure 12) 6. Remove fuel injectors from cylinders 6, 7 and 8. (WSM, Section C, use Ford Special Service Tool Number ) PAGE 9

10 7. Inspect all injectors for D-ring and/or snap-ring 14. Insert a 10 long 1/4 locking extension with a damage at the injector to high pressure oil rail T27 locking Torx bit through cylinder number 7 plug location. exhaust push rod hole and loosen the hold down bolt. Use a magnet through the standpipe 8. Plug oil drain holes in cylinder head prior to hole to remove bolt. (The extension will be on a removing the rocker arms. Remove intake and slight angle, have someone under the vehicle exhaust rocker arms from cylinders number 7 watch from the rear cover area to guide the and number 8 then remove the push rods (See socket on the bolt head of the branch tube hold WSM, Section C, use Ford special down). service tool number The rocker arm plastic retaining clips may break upon removal. Make sure all the pieces are removed from the THE BOLT HEAD IS NOT VISIBLE ON THIS SIDE. head). CAUTION 9. Rotate engine one (1) full revolution, see WSM, IF THE TORX BIT IS DROPPED IT WILL BE Section C rocker arm removal procedure. NECESSARY TO REMOVE THE CYLINDER HEAD TO RETRIEVE IT. 10. Remove exhaust rocker arm from cylinder number 6 and push rod (leave tool in place). 15. Remove the branch tube from the engine and replace high-pressure branch tube. 11. Remove the rear cover following WSM, Section C. Cut the sealant at the rear cover T 16. Pack the branch tube bolt holes with grease joints for the bedplate gaskets and and install retaining bolts in the branch tube high-pressure pump cover gasket before fully flush with the bottom. removing. 17. If the high pressure pump was removed it needs to be installed at this point. Torque the USE A LONG PUTTY KNIFE OR RAZOR BLADE mounting bolts to 26 lb-ft (35 N m). TO SEPARATE THE BED PLATE GASKETS TO PREVENT DAMAGE. DO NOT STRETCH THE 18. Install the two (2) 8 mm bolts into the branch BEDPLATE GASKETS OR THE BEDPLATE WILL tube adapter. HAVE TO BE REMOVED. 19. Install a new high-pressure oil branch tube into 12. Loosen the two (2) 8 mm bolts that hold the the block. Start the two (2) 8 mm bolts from the branch tube adapter to the branch tube. (Use discharge tube into the branch tube. Have open end / box end wrench - thin) someone under vehicle guide and start the hold down bolts through cylinder 7 and cylinder Insert a 10 long 1/4 locking extension with a push rod holes. While tightening the branch T27 locking Torx bit through cylinder number 6 tube hold down bolts maintain positive outward exhaust push rod hole. Use a magnet through pressure on the branch tube. Torque the the standpipe hole in the head to remove the retaining bolts to 10 lb-ft (14 N m). bolt (the extension will be on a slight angle, have someone under the vehicle watch from 20. Tighten the two (2) 8 mm discharge tube bolts. the rear cover area to guide the socket on the Torque to 11 lb-ft (15 N m). bolt head of the branch tube hold down). CAUTION IF THE TORX BIT IS DROPPED IT WILL BE NECESSARY TO REMOVE THE CYLINDER HEAD TO RETRIEVE IT. PAGE Clean the rear engine cover. Install a new gasket. Add Motorcraft Ultra Silicone Sealant to the bedplate and the high pressure pump covers joints. Install the rear engine cover. Torque to 18 lb-ft (24 N m). 22. Install a new rear main seal using Ford Special Service Tool Number Install rear main seal dust cover. 24. Install the flywheel. NEW FLYWHEEL BOLTS REQUIRED.

11 25. Install the starter. OPERATION DESCRIPTION TIME A Super Duty, 1.0 Hr. 26. Install push rod and rocker arm in cylinder 2005 Excursion (6.0L) number 6. Time Includes: Checking 27. Rotate engine 1 full revolution. DTCs and ICP voltage; ICP Graph Comparison 28. Install push rods and rocker arms in cylinders Test(s); Pin Point Test R number 7 and number 8. and Road Test. This Labor Operation Can Only Be 29. Install the upper and lower crankcase to head Claimed With Operation B. tubes (stand pipes), replace if damaged. (Do Not Use With Any Labor Operations Outside 30. Install fuel injectors. Of This TSB) 31. Install high-pressure oil rails, per WSM, Section A Econoline 1.1 Hrs C. (6.0L) Time Includes: Checking DTCs and ICP 32. Install the valve covers. voltage; ICP Graph 33. Install the (FICM). Comparison Test(s); Removing Engine Cover; 34. Install the air filter housing. Pin Point Test R and Road Test. This Labor Operation 35. Install coolant overflow tank. Can Only Be Claimed With Operation B. (Do Not Use 36. Install right side charge air cooler (CAC) tube. (Hot Side) With Any Labor Operations Outside Of This TSB) 37. Install the transmission, see the appropriate B Super Duty, 1.3 Hrs. model year WSM, Section Excursion (6.0L): Replace The IPR Valve. 38. Check engine oil level and refill as required. This Labor Operation Can Return to customer. Be Claimed With Any Of The Labor Operations In PART NUMBER PART NAME This Article. (Do Not Use 4C3Z-9B246-C ICP Fitting Kit With Any Labor Operations 5C3Z-9J332-C Branch Tube Outside Of This TSB) 3C3Z-6379-BA Flywheel Bolt (Automatic Transmission-10 per repair required) B Econoline 3C3Z-6379-CA Flywheel Bolt (Manual-10 per repair (6.0L): Replace The IPR 0.7 Hr. required) Valve. This Labor TA-29 Motorcraft Ultra Silicone Sealant Operation Can Be Claimed With Any Of The Labor WARRANTY STATUS: Eligible Under Provisions Of Operations In This Article. New Vehicle Limited (Do Not Use With Any Warranty Coverage Labor Operations Outside IMPORTANT: Warranty Of This TSB) coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. PAGE 11

12 081806C Super Duty, 1.8 Hrs D Econoline 4.5 Hrs Excursion (6.0L) (6.0L) Time Includes: Time Includes: Checking Replacing STC And/Or DTCs and ICP Voltage; High Pressure Pump; ICP Graph Comparison Perform Air Pressure Test Test(s); Pin Point Test R; At Test Port On High RPM Run Up Pressure Oil Pump. This Test(s); Air Pressure Labor Operation Must Be Test(s) at ICP Port and Claimed With Operation C; Road Tests. This Labor Can Be Claimed With B Operation Can Be Claimed And Either E Or F. (Do With Any Of The Labor Not Use With Any Labor Operations In This TSB Operations Outside Of This Except A. (Do Not Use TSB) With Any Labor Operations E Super Duty, 10.8 Outside Of This TSB) 2005 Excursion (6.0L 4X4 Hrs C Econoline 2.0 Hrs. Automatic Transmission) (6.0L) Time Includes: Time Includes: Replacing Checking DTCs and ICP Branch Tube; Inspect: All Voltage; ICP Graph Injectors, Port Plug Comparison Test(s); D-rings, Standpipes and Removing Engine Cover; Replace as Necessary. Pin Point Test R; 3-4 This Labor Operation Must 000RPM Run Up Test(s); Be Claimed With Operation Air Pressure Test(s) at C and D; Can Also Be High Pressure Pump and Claimed with B. (Do Not Road Tests. This Labor Use With Any Labor Operation Can Be Claimed Operations Outside Of This With Any Of The Labor TSB) Operations In This TSB E Super Duty, 10.0 Except A. (Do Not Use 2005 Excursion (6.0L 4X2 Hrs. With Any Labor Operations Automatic Transmission) Outside Of This TSB) Time Includes: Replacing D Super Duty, 4.9 Hrs. Branch Tube; Inspect: All 2005 Excursion (6.0L) Injectors, Port Plug Time Includes: Replacing D-rings, Standpipes and STC And/Or High Pressure Replace as Necessary. Pump; Perform Air This Labor Operation Must Pressure Test At ICP Port Be Claimed With Operation and Air Pressure Test At C and D; Can Also Be Test Port on High Claimed with B. (Do Not Pressure Oil Pump. This Use With Any Labor Labor Operation Must Be Operations Outside Of This Claimed With Operation C; TSB) Can Be Claimed With B And Either E Or F. (Do Not Use With Any Labor Operations Outside Of This TSB) PAGE 12

13 081806E Super Duty F Super Duty, 4.2 Hrs. (6.0L 4X4 Manual Hrs Excursion (6.0L): Transmission) Time Remove Valve Covers and Includes: Replacing Branch Perform Under Valve Tube; Inspect: All Injectors, Cover Leak Test, Time Port Plug D-rings, Includes Removing and Standpipes and Replace Inspecting: High Pressure as Necessary. This Labor Oil Rails, D-Rings, Operation Must Be Standpipes, Injectors And Claimed With Operation C Replace as Necessary. and D; Can Also Be This Labor Operation Must Claimed with B. (Do Not Be Claimed With Operation Use With Any Labor C; Can Also Be Claimed Operations Outside Of This with B and D. (Do Not Use TSB) With Any Labor Operations E Super Duty 8.9 Hrs. Outside Of This TSB) (6.0L 4X2 Manual F Econoline 7.8 Hrs. Transmission) Time (6.0L): Remove Valve Includes: Replacing Branch Covers and Perform Under Tube; Inspect: All Injectors, Valve Cover Leak Test, Port Plug D-rings, Time Includes Removing Standpipes and Replace and Inspecting: High as Necessary. This Labor Pressure Oil Rails, Operation Must Be D-Rings, Standpipes, Claimed With Operation C Injectors, And Replace as and D; Can Also Be Necessary. This Labor Claimed with B. (Do Not Operation Must Be Use With Any Labor Claimed With Operation C; Operations Outside Of This Can Also Be Claimed with TSB) B and D. (Do Not Use E Econoline 18.0 With Any Labor Operations (6.0L) Time Includes: Hrs. Outside Of This TSB) Replacing Branch Tube; G Super Duty, 2.9 Hrs. Inspect: All Injectors, Port 2005 Excursion (6.0L): Plug D-rings, Standpipes Perform High Pressure And Replace as Pump Test, Time Includes Necessary. This Labor Removing and Installing Operation Must Be Valve Covers. This Labor Claimed With Operation C Operation Must Be and D; Can Also Be Claimed With Operation C; Claimed with B. (Do Not Can Be Claimed With Use With Any Labor either Operations D Or H Operations Outside Of This and B. (Do Not Use With TSB) Any Labor Operations Outside Of This TSB) PAGE 13

14 081806G Econoline 5.7 Hrs H Econoline 2.7 Hrs. (6.0L): Perform High (6.0L): Perform Under Pressure Pump Test, Time Valve Cover Leak Test Includes Removing and with Valve Covers Installing Valve Covers. Previously Removed. This Labor Operation Must Time Includes Removing Be Claimed With Operation and Inspecting: High C; Can Be Claimed With Pressure Oil Rails, either Operations D Or H D-Rings, Standpipes, and B. (Do Not Use With Injectors And Replace as Any Labor Operations Necessary. This Labor Outside Of This TSB) Operation Must Be H Super Duty, 1.7 Hrs. Claimed With Operation C 2005 Excursion (6.0L): and G; Can be claimed Perform Under Valve with operation B. (Do Not Cover Leak Test with Use With Any Labor Valve Covers Previously Operations Outside Of This Removed. Time Includes TSB) Removing and Inspecting: DEALER CODING High Pressure Oil Rails, CONDITION D-Rings, Standpipes, BASIC PART NO. CODE Injectors And Replace as 9B Necessary. This Labor Operation Must Be Claimed With Operation C and G; Can be claimed with operation B. (Do Not Use With Any Labor Operations Outside Of This TSB) PAGE 14

15 Figure 13 - Article PAGE 15

16 Figure 14 - Article PAGE 16

17 Figure 15 - Article PAGE 17

18 Figure 16 - Article PAGE 18

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