2003 6.0L BIBLE TABLE OF CONTENTS
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Power Stroke Diesel Engine Running Changes By Model Year
Diesel Doctor's tech pubs page.

6.4L Overview

2005 6.0L Bible Update

OVERVIEW
Horsepower &Torque
Specifications
Firing Order
Engine Serial Number
FICM Serial Number and Calibration Label
Emissions Label

COMPONENT LOCATIONS

Front of Engine Left Front of Engine
Left Side of Engine Left Rear of Engine
Rear of Engine Right Rear of Engine
Right Side of Engine
Top of Engine
Rocker Carrier, Cylinder Head, Rear Gear Train
Dual and Single Mass Flywheels, Crankshaft Discoloration

COOLING SYSTEM
System Flow
Flow: Front Cover
Flow: Oil Cooler
Flow: EGR Cooler
Water Pump and Front Cover
Injector Sleeve
Glow Plug Sleeve
Coolant Recovery Bottle

LUBRICATION SYSTEM
Features
Oil Flow, Oil Pan / Bed Plate
Pick up Tube, Pressure Regulator, Gerotor Oil Pump
Front Cover, Oil Cooler, Housing and Filter Base
Oil Filter base and Valve, Oil Filter, Oil Reservoir and Screen
Oil Flow at Reservoir, Turbo Oil Supply and VGT Control, Turbo Oil Drain

FUEL SUPPLY SYSTEM
Features
Fuel Flow
HFCM
Engine Mounted Fuel Filter, Fuel Pressure Regulator, Fuel Check Valve

AIR MANAGEMENT SYSTEM
System Components / Features
System Flow
Air Filter / Filter Minder, Air Filter Element, Charged Air Cooler
VGT Turbo Features, VGT Compressor, VGT Turbine
VGT Control Valve, VGTCV Flows (Operation)
VGT Turbine Vanes, Closed, Partially Closer, Open
EGR Valve, EGR Flow, EGR Cooler
EGR Throttle, Intake Manifold

FUEL MANAGEMENT SYSTEM
Generation II Management System Diagram, Major Components, Advantages
High Pressure Oil Flow
Oil System Schematic
High Pressure Pump & Cover, IRP, Oil Rail with AWA Feature
Fuel Injector Features
Intensifier Piston, Plunger & Barrel, Injector Nozzle
Three Stages of Injection, Fill, Main Injection, End or Main Injection
Main Ijection Step 1 and Step 2
End of Main Injection Step 1 and Step 2

ELECTRICAL COMPONENTS (Link to Sensor Overview)
Generation II Components Sensor Overview
AP (Accelerator Padel)
Baro (Barometric Pressure)
CKP (Crankshaft Position)
CMP (Camshaft Position)
ECT (Engine Cooant Temp)
EGRVP (Exhaust Gas Recirculation Valve Position)
EOP (Engine Oil Pressure Switch)
Hint: Get a real oil pressure gauge!
EOT (Engine Oil Temp)
EP (Exhaust Pressure)
IAT1 (Intake Air Temp #1)
IAT2 (Intake Air Temp #2)
ICP (Injection Control Pressure)
MAF (Mass Air Flow)
MAP (Manifold Absolute Pressure)
Actuators Overview
IPR (Injection Pressure Regulator)
EGR (Exhaust Gas Recirculation)
VGTCV (Variable Geometry Turbocharger Control Valve)
Other Electrical Components
FICM (Fuel Injection Control Module)
PCM (Power Train Control Module)
Glow Plug System
GPCM (Glow Plug Control Module)
Glow Plug, Glow Plug Sleeve, Glow Plug Buss Bar
Glow Plug System Diagnostics

UNIQUE SERVICE PROCEDURES
Oil Filter Replacement
Engine mounted Fuel Filter Replacement
(Secondary Filter)
Injector Removal
Injector Removal continued
Injector O-Ring Replacement
Injector O-Ring Replacement continued
Injector Installation
Cylinder Head Rocker Carrier , Rocker Arms / Bridges, Cylinder Head & Rocker Fulcrums Removal
Glow Plug / Injector Sleeve Removal & Installation
EGR Valve Removal

EGR Cooler Removal & Installation
Turbocharger Oil Supply Removal
Crankcase Ventilation Removal / Oil Carryover

Tubocharger Oil Drain Tube, Intake Manifold and IRP Valve Removal
High Pressure Pump Cover, Front Cover Removal, Front Cover Dowel Locations
Gerotor Oil Pump, Front Cover Sealant Application,
Glow Plug / Buss Bar Removal

Crankshaft Rear Seal Dust Cover, Crankshaft Primary Flange

GENERAL DIAGNOSTICS
Diagnostic Codes

APPENDIX

Index

Last Update: October 25, 2006

D. Pruyn

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