303-01D-i Engine 6.0L Diesel 303-01D-i SECTION 303-01D Engine 6.0L Diesel CONTENTS PAGE SPECIFICATIONS... 303-01D-2
303-01D-2 Engine 6.0L Diesel 303-01D-2 SPECIFICATIONS Mteril Fill Cpcity Gsket Mker TA-16 Hevy Truck PAG Refrigernt Compressor Oil YN-24 WSK- M2G348-A5 WST- M1C231-B2 Mteril(Continued) Fill Cpcity RTV Silicone Selnt TA-31 Silicone Brke Cliper Grese nd Dielectric Compound XG-3-A ESE-M1C171- A High Temperture Nickel Anti- Seize Lubricnt XL-2 Metl Brke Prts Clener PM-4-A or PM-4- B (US); CPM-4 (Cnd) Motorcrft Premium Gold Engine Coolnt VC-7-B (US); CVC-7-A (Cnd); or equivlent Motorcrft SAE 15W-40 Super Duty Diesel Motor Oil XO-15W40-QSD (US); CXO-15W40- LSD12 (Cnd); or equivlent Multi-Purpose Grese XG-4 nd/or XL-5 Penetrting nd Lock Lubricnt (US); Penetrting Fluid (Cnd) XL-1 (US); CXC-51-A (Cnd) ESE-M12A4- A WSS- M97B51-A1 WSS- M2C171-E ESB-M1C93- B 14L (15 qt) with filter Thred Selnt with PTFE TA-24 Thredlock 262 TA-26 Generl s WSK- M2G350-A2 WSK- M2G351-A6 Generl s Engine Displcement 6.0 liter (365 cubic inch) Number of cylinders 8 Bore Stroke 95 mm (3.74 105 mm (4.13 Firing order 1-2-7-3-4-5-6-8 Oil pressure minimum 82.7 kp (12 psi) t 700 rpm, 165.5 kp (24 psi) t 1,200 rpm nd 310.3 kp (45 psi) t 1,800 rpm with engine t operting temperture Oil cpcity 14.1 liters (15 qurts) with filter Compression rtio 18.0:1 Cylinder hed nd vlve trin Cylinder hed gsket surfce fltness Cylinder hed thickness Combustion chmber volume Vlve rrngement (front to rer) 0.1 mm ( 0.004 95 mm (3.74
303-01D-3 Engine 6.0L Diesel 303-01D-3 Generl s(continued) Generl s(continued) Vlve guide bore dimeter 7.003-7.029 mm (0.276-0.277 Lobe lift Intke 5.744 mm (0.2261 Vlve stem dimeter 6.947-6.965 mm (0.2735-0.272 Lobe lift Exhust 5.832 mm (0.2296 Vlve stem-to-guide 0.140 mm (0.0055 mximum Vlve hed dimeter Allowble lobe lift loss Journl dimeter 0.51 mm (0.02 61.987-62.013 mm (2.440-2.441 Vlve fce runout (T.I.R. mx) 0.038 mm (0.015 Cmshft journl bering inside dimeter 62.05-62.14 mm (2.443-2.446 Vlve fce ngle Vlve fce ngle Vlve set width Vlve set width Exhust 37.5 degrees Intke 30 degrees Exhust 1.80-2.56 mm (0.071-0.101 Intke 1.48-2.24 mm (0.058-0.088 Cmshft journl-to-bering 0.037-0.153 mm (0.0015-0.0060 Runout End ply Cylinder block 0.051-0.211 mm (0.002-0.008 Vlve set runout Vlve set ngle Vlve set ngle Vlve spring free length Vlve spring solid height Vlve spring compression pressure 0.0035 mm (0.0014 Exhust 37.5 degrees Intke 30 degrees 51.96 mm (2.045 36.1 mm (1.42 46.30 mm @ 340 +/- 17 N (1.82 in 76.5 +/- 3.8 lb-ft) Vlve spring instlled height Vlve spring instlled pressure Roller follower rtio Hydrulic lsh djuster Dimeter Clernce-to-bore Service limit Hydrulic lekdown rte Collpsed lsh djuster gp Cmshft Ger bcklsh 0.179-0.315 mm (0.007-0.012 Cylinder bore dimeter Cylinder bore mximum tper Cylinder bore mximum out of round Min bering bore inside dimeter Cmshft bering bore inside dimeter Hed gsket surfce fltness Crnkshft dimeter Stndrd size dimeter 0.254 mm (0.010 undersize 94.999-95.001 mm (3.7401-3.7402 0.076 mm (0.003 0.05 mm (0.002 85.99-86.01 mm (3.3854-3.3862 65.98-66.02 mm (2.597-2.599 0.10 mm (0.004 cross the totl re 0.05 mm (0.002 cross ny 150 mm (5.9 x 150 mm (5.9 re 0.025 mm (0.001 cross ny 25 mm (0.98 x 25 mm (0.98 re 80.9873-81.0127 mm (3.188-3.150 80.7333-80.7587 mm (3.178-3.140
303-01D-4 Engine 6.0L Diesel 303-01D-4 Generl s(continued) Generl s(continued) dimeter 0.508 mm (0.020 undersize 80.4793-80-5047 mm (3.168-3.130 Piston ring groove width (mesured over 2.08 mm (0.082 guge pins) Replcement limit 94.290 mm (3.7122 dimeter 0.762 mm (0.030 undersize mximum tper mximum out-of-round -tocylinder block Connecting rod journl dimeter Connecting rod journl mximum tper Connecting rod journl mximum out-of-round Crnkshft mximum end ply Piston nd connecting rod Piston dimeter Stndrd size Piston dimeter 0.254 mm (0.010 oversize Piston dimeter 0.508 mm (0.020 oversize Piston dimeter 0.762 mm (0.030 oversize Piston-to-cylinder bore Piston ring end gp top compression Piston ring end gp intermedite compression Piston ring end gp oil control Piston ring groove width (mesured over 2.08 mm (0.082 guge pins) 80.2253-80.2507 mm (3.158-3.120 0.020-0.086 mm (0.0008-0.0034 0.508 mm (0.020 94.9460-94.9186 mm (3.737-3.738 95.1738-95.1992 mm (3.747-3.748 95.4278-95.4532 mm (3.757-3.758 95.6818-95.7072 mm (3.767-3.768 0.0441-0.0909 mm (0.0017-0.0036 0.29-0.55 mm (0.011-0.021 1.40-1.66 mm (0.055-0.065 0.24-0.50 mm (0.009-0.019 Upper limit 94.469 mm (3.7192 Piston ring width Piston ring-to-groove Piston pin bore dimeter Piston pin dimeter Piston pin length Piston pin-to-piston fit Connecting rod-to-pin Connecting rod pin bore dimeter Connecting rod length (center to center) Connecting rod mximum llowed bend Connecting rod mximum llowed twist Connecting rod bering bore dimeter Connecting rod bering-tocrnkshft Connecting rod side Exhust mnifold wrpge - mximum llowble (cold) Intke mnifold wrpge - between ports Intke mnifold wrpge - totl Oil pump end (inner nd outer rotor to housing) 33.9975-34.0025 mm (1.3385-1.3387 65.073-65.327 mm (2.5619-2.5719 0.013-0.022 mm (0.0005-0.0009 176 mm (6.929 72.987-73.013 mm (2.8735-2.8745 0.0203-0.0837 mm (0.0008-0.0033 0.0762 mm (0.003 0.13 mm (0.005 0.25 mm (0.0010 0.025-0.095 mm (0.001-0.004
303-01D-5 Engine 6.0L Diesel 303-01D-5 Generl s(continued) Torque s(continued) Oil pump rdil (between outer rotor nd housing) Vibrtion dmper mounting re runout (mx) Push rod runout (mx) High pressure oil pump ger bcklsh Lower crnkcse groove depth nd width 0.17-0.295 mm (0.007-0.012 0.05 mm (0.002 0.25 mm (0.01 0.179-0.315 mm (0.007-0.0124 4.242 mm (0.167 mximum EGR cooler, (M8 x 16) 31 23 EGR cooler stud (M6 X 55 X 20) 13 10 Crnkcse brether nuts 7 62 Cylinder hed bolt sequence nd torque b Fuel injector hold-down bolt 33 24 Rocker rm fulcrum plte 31 23 Glow plugs 19 14 Refer to the Cylinder Hed Distortion procedure in this section. Torque s Air inlet duct clmp 5 44 Turbochrger exhust dpter V-clmp Exhust tube to exhust mnifold flnge (left side) Exhust tube to exhust mnifold flnge (right side) Turbochrger flnge to exhust/egr tube (right side) Turbochrger mounting 12 9 27 20 27 20 27 20 38 28 Turbochrger pedestl 31 23 Turbochrger oil supply tube 24 18 Exhust mnifold flnge 38 28 Intke mnifold flnge 11 8 Intke mnifold het shield 11 8 EGR vlve mounting 13 10 EGR clmp, V-bnd 6 53 ICP sensor 12 9 Oil ril ssembly b High pressure tube (cse to hed) 45 33 Oil ril check vlve 34 25 Oil ril vent plugs 11 8 Vlve cover nd studs 8 71 Oil drin pn plug 44 32 Front cover module 24 18 Thermostt housing retining Coolnt pump mounting 23 17 23 17 Vibrtion dmper mounting b Oil pump housing retining 8 71 Connecting rod bering b Lower crnkcse min bering cp b Lower crnkcse outer (M8 x 30) 24 18 Oil pickup tube flnge 13 10 Piston cooling jet mounting 13 10 bolt c Cm follower mounting bolt 13 10
303-01D-6 Engine 6.0L Diesel 303-01D-6 Torque s(continued) Cmshft thrust pltemounting 31 23 Coolnt heter 41 30 Oil cooler mounting (6mm) Oil cooler mounting (8mm) Oil cooler-to-oil cooler cover 10 89 22 16 22 16 Torque s(continued) Glow plug 19 14 Glow plug rely 11 8 High pressure oil pump cover High pressure oil pump mounting High pressure oil pump dischrge tube mounting (top of pipe) 11 8 24 18 8 71 Oil cooler-to-oil cooler cover nuts 22 16 Rer het shield (M6 x 1.0 x 1.2) 11 8 EGR cooler coolnt supply port cover (M6) 10 89 Rer het shield (M10 x 1.5 x 16) 49 36 Oil filter housing (torx) 15 11 Bnjo bolt with copper seling wshers 38 28 Oil filter return tube bolt, new bse 5 44 Bnjo bolt with Viton seling wshers 25 18 Oil filter return tube bolt, reinstlltion 3 27 Fuel filter plug ssembly (bck of hed) 27 20 Crnkshft position (CKP) sensor 11 8 Flywheel/flexplte mounting 94 69 Cmshft position (CMP) sensor 11 8 Fuel supply nd return tubes t filter 43 32 Injection control pressure (ICP) sensor 12 9 Right nd left hed supply tubes t filter 26 19 Injection pressure regultor (IPR) vlve Mnifold ir temperture (MAT) sensor Exhust bck pressure tube ssembly Exhust bck pressure (EBP) sensor Exhust bck pressure (EBP) sensor brcket 50 37 17 13 30 22 12 9 12 9 Lower oil pn bolt 13 10 Upper oil pn (M6) 13 10 Engine coolnt temperture (ECT) sensor 12 9 Front, lifting eye (M10 x 30) 41 30 Rer, lifting eye (M10 x 35) 41 30 Automtic trnsmission tube nut 8 71 Engine ground strp bolt 10 89 Strter positive cble nut 12 9 Strter control wire nut 6 53 Torque converter nut 35 26 Motor mount nuts 112 83 Turbo down pipe 40 30 Trnsmission-to-engine 47 35
303-01D-7 Engine 6.0L Diesel 303-01D-7 Torque s(continued) Trnsmission tubes mounting brcket 10 89 Upper oil pn (M8) 31 23 Trnsmission cooler 8 71 Power steering cooler 11 8 Bttery crossover cble nut 12 9 Power steering pump bolt 25 18 Bttery ground cble-toengine block Air conditioning compressor 47 35 25 18 A/C mnifold bolt 21 15 Coolnt pump mounting bolt 23 17 Coolnt pump pulley 31 23 Cooling fn sttor 40 30 Fn clutch hub-to-coolnt pump 133 98 Belt idler pulley 47 35 Belt tensioner 25 18 Crnkshft pulley (dul lterntors) Alterntor mounting brcket (dul lterntors) 47 35 47 35 Strter mounting 25 18 Solenoid wire nut 6 53 Stndrd Torque Pipe Thred Thred Size Torque 1/8 in NPT 10.2 Nm (7 lb-ft) 1/4 in NPT 13.6 Nm (10 lb-ft) 3/8 in NPT 20.4 Nm (15 lb-ft) 1/2 in NPT 34 Nm (25 lb-ft) 3/4 in NPT 40.8 Nm (30 lb-ft) Tolernces re ± 10% of nominl vlue. Stndrd Torques Clss 10.9 Metric Bolts nd Studs Thred Dimeter Thred Pitch (mm/thred) Torque 6 mm 1 13 Nm (10 lb-ft) 8 mm 1.25 31 Nm (23 lb-ft) 10 mm 1.5 62 Nm (45 lb-ft) 12 mm 1.75 107 Nm (79 lb-ft) 14 mm 2 172 Nm (127 lbft) 15 mm 2 216 Nm (159 lbft) 16 mm 2 266 Nm (196 lbft) 18 mm 2.5 368 Nm (272 lbft) 20 mm 2.5 520 Nm (384 lbft) Bttery cble nut 12 9 Tolernces re ± 10% of nominl vlue. b c Apply High Temperture Nickel Anti-Seize Lubricnt (XL-2) to the threds prior to ssembly. Refer to the procedure in this section. Apply Thredlock 262 to bolt threds prior to ssembly. Stndrd Torques Clss 12.9 Metric Bolts nd Studs Thred Dimeter Thred Pitch (mm/thred) Torque 6 mm 1 15 Nm (11 lb-ft) 8 mm 1.25 36 Nm (27 lb-ft)
303-01D-8 Engine 6.0L Diesel 303-01D-8 Stndrd Torques Clss 12.9 Metric Bolts nd Studs (Continued) Thred Dimeter Thred Pitch (mm/thred) Torque 10 mm 1.5 72 Nm (53 lb-ft) 12 mm 1.75 126 Nm (93 lb-ft) 14 mm 2 201 Nm (148 lbft) 15 mm 2 252 Nm (186 lbft) Stndrd Torques Clss 12.9 Metric Bolts nd Studs (Continued) Thred Dimeter Thred Pitch (mm/thred) Torque 16 mm 2 311 Nm (230 lbft) 18 mm 2.5 430 Nm (317 lbft) 20 mm 2.5 608 Nm (448 lbft) Tolernces re ± 10% of nominl vlue.