YW |POWER STROKE I tS vs @ G.OL Power Streke Diesel Wirreet Injection Wwlieciareed Wiesel Lugine New 2005 EGE Saities Super Wwtay Features, Descriptions, and 2004 Running Changes 8.0L Power Stroke Diesel2005 6.0L DIT UPDATES a ] 2004 Running Changes 2004 Running Changes + Fuel Supply Line + Fuel supply ine includes all associated ‘components. * During the 2004 MY the rear crankshaft oil seal was redesigned for improved performance. This change applies to both, the production seal and the service seal * VGT Control Valve + Turbocharger Bearings + Rear Crankshaft Oil Seal Fuel Supply Line Trap + Atrap was added to the fuel supply line to prevent fuel from draining out of the secondary fue! fter housing. = This new fuel supply line is attached to the fuel fiter Nousing using @ banjo bolt and is: sealed using two copper washers, These washers must be replaced any time the Bolt is loosened + NOTE: This fuel line cannot be retrofitted to earlier versions of the 6.0L engine. The fuel filter housing has been modified to accept the banjo bolt and washers. EE VGT Control Valve + The updated control valve provides faster response along with improved stability, + A200 micron screen has been added to the ll inlet of the control valve + NOTE: The updated VGT control valve can be used on the 2003 and 2004 MY turbochargers. OIL INLET SCREEN.2005 6.0L DIT UPDATES SES 2005 Hardware Changes Component | F-Series | E-Series | Excursion Ror | wow | nue [Senet Front Cover | Inlet Port | Inlet Port | Carryover EGR Valve |New Seal] New Seal | Carryover EGR Throttle | Deleted | Deleted Carryover, Horsepower and Torque eran peed trl Torque {fb} —Powor [bhp] 6 Turbocharger Bearings ‘The size of the floating bearings in the rotating group of the turbocharger has Increased. The two bearings have each Increased in length by tm. ‘The bearing updates make the rotating group more robust and reduce shaft motion effects due to engine vibration inputs 2005 Hardware Changes ‘The Hardware changes for the 2005 MY are for F-Series and E-Series vehidles only unless otherwise noted. The serial number break for Indianapolis built engines is (6344943. Production began June 29, 2004. Excursion vehicles carryover the 2004 MY engine for the first part of the 2005 MY. EGR Throttle includes all associated components. High-pressure pump includes all associated eamponents Horsepower and Torque Torque has been increased to 570 ft. Ibs Horsepower remains the same at 325 HP. Note: Econoline 6.0L diesel engine horsepower and torque will remain the ‘same for 2005 model year (235 HP and 440 ftlb of torque).2005 6.0L DIT UPDATES High-Pressure Pump ‘+ The high-pressure pump has changed to a V4 style piston pump. + The flow specifications are comparable to the previous (swash plate style) pump. + The V4 pump will provide improved high-pressure oil system respanse at low engine speeds. + The long term durabllty of the high-pressure pump has been improved due to less wear ‘area inside of the pump. High-Pressure Pump Gover * Aredesigned cast aluminum high-pressure pump cover will be used in 2005 MY due to the use of a new style high-pressure pump. + The IPR valve is now mounted in the top of the high-pressure pump instead of the pump * If removal of the pump cover is necessary, the IPR valve must be removed first + NOTE: For the purpose of illustration the IPR valve heat shiold has boon removed. Be sure to reinstall the heat shield after any service is performed, High-Pressure Pump Cover Removal + The high-pressure pump is sealed to the pump cover with an o-ring around the bady of the pump. ‘+ The oil drain for the turbocharger remains in the high-pressure pump cover. + NOTE; Be sure to cut the silastic T- joint that seals the high-pressure pump cove rear cover, and cylinder block together prlor to removing the high-pressure pump cover.2005 6.0L DIT UPDATES High-Pressure Pump/Discharge Tube + The pump Is driven by the camshaft gear as In previous model years + The high-pressure pump discharge tube has 1 modified to accommadate the new high-pressure pump. High-Pressure Oil Branch Tube. + The high-pressure pump discharge tube and branch tube nave been redesigned to Incorporate the new style high-pressure pump, + The two bolts holding the discharge tube and DISCHARGE TUBE BOLTS the branch tube together are removed when removing the high-pressure pump. The disenarge tube should ba removed with the high-pressure pump, NOTE: The 2005 MY high-pressure pump, pump cover, discharge tube, and branch tube, are not interchangeable with 2003 and 2004 MY engines. However, the standpipes did not chang IPR Valve ‘The 2005 MY IPR valve uses 2 150 micron perforated plate edge fitter. This is an improvement from the 200 micron fiter on provious models. NOTE: For the purpose of illustration the IPR valve heat shield has been removed. Be sure to reinstall the heat shield after any service Is porformed. NOTE: The IPR valve Is not interchangeable with 2003 and 2004 MY engines. PERFORATED PLATE EDGE FILTER 422005 6.0L DIT UPDATES High-Pressure Gil Rail Ball Tubes ‘+ The length of the ball tube has been increased by 2mm ta aid in assembly, This is to reduce the potential risk of damaging the upper o-ring during the installation of the high-pressure oll rail + NOTE: The 2005 MY high-pressure oil rail is not interchangeable with 2004 MY engines. + NOTE: The 2004 MY high-pressure oil rail can be indentified by the C1 suffix of the International part number. The 2005 MY high-pressure oil rail can be identified by the number “5” stamped into one of the ‘endeaps of the rail. Front Cover + The coolant inlet parts on the front cover have been repositioned to accomodate the new power steering pump design + NOTE; The 2005 MY front cover is not interchangeable with 2003 and 2004 MY engines. EGR Valve + The EGR shaft seal has beon improved to reduce exhaust gas leaks past the EGR valve vent holes, + The shat seal improvement requires an increased retum spring tension, + NOTE: The 2005 MY EGR valve and the 2003/2004 MY EGR valves are not interchangeable. + NOTE: The 2005 MY EGR valve can be Identified by the part number 4043H located on the top of the valve. 152005 6.0L DIT UPDATES Exhaust Up-Pipe Scoop. + An exhaust gas scoop in the exhaust Up-pipe increases exhaust flow to the EGR cooler. * This improves the performance of the EGR valve without the use of the throttle plate, Intake Manifold Divider Plates * Two divider plates have been incorporated Into the intake manifold to provide equal distribution of cooled exhaust gases into bott cylinder heads. EGR Throttle Plate * EGR throttle plate (EGRTP) has been deleted from the air inlet of the intake manifold for the 2005 MY. + The 6.01 engine no langer needs the EGR. throttle plate to assist the flow of exhaust gases through the EGR valve.DIAGNOSTIC CODES [3 Sete Key On Eman OF OED) R= Sat at Rey On Eng Fran ROER) mt “Add change 2008 MY et use en 806 Forages or BON coe Sa Ta eC ST SCRE TO ARTES Spe So Cel SORTS CP Jeo PT VE A ea co TDagpeie a em i Ny Sa a oa PSEC p heen I Eecaapanieannoon oven" | NADIR Cora [ois ees Cenpee Bank WAP ai Ver um WP Eo Spon Gare Sorex Ce Wey |p|] nt Ar Terportre Sones Cieat ————}5 ag (UY dg Fiche for aru change a IAT —|BAY 7 Wsred Senex. Speman PEM | 3 a RT Dae UA aN eT RD [sdsronroatis beste 158 40 elactennoMie ponarhan 008 [ Naos = Vols low Creat Lav pik osten NAF serar ara lew ppulwas deeds ng |Oneq WAP ensue Scab Saved seaon POUR SIGN ATN |FDED Sol Te! arg contro Suprelrentoing. 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Tulse dng ost os. |Destmocld/Desharged Belly Open PM pr fuly FCN — 7 aaa PEN | eyndaes Gow Pg Creat |B. Gjinder« Gow Pug Creut IR Gjner€ Gow Pug Creut ‘Clon pu [clon aig 3 fuo [clon sug flo [clon si #5 fae [Operiertod seu fel sew plug, ood CK |Operlsoted seu. tly gow plug, aled GCN ‘Peetsc:0 Rowe Gomi Cait ‘Sor a ala Cpe ely go nd =e ‘foe? €or eng et ‘or py as ‘awe set fly Go nls CHCA IR [Gylesier ® Gow Plug Creu ‘Sloman low plug. failed GECN son Pig Gontio Moule to PCM Communication | ‘BN plug con meduiB SomerERICAKON Ihe alive Opershorted cicuk. fated GPCM. falled FCN (Sea | FR Fenn Crs Sere Fense | _. a cbt bp cr cer pt a POM ld ang KOER “Porc IR ote Serica poER chit |p Ee PCM at apa KOER Ea [et FR KOER ro abo compete KOER ated TR te Foe rab croat (Condes rt mat Trees fat naan [AG, Pang Era. Ckzh, PRUDL, (EOT. ETC) Tuy sara, Open Sha oraut T a (R000 Sysore Resaness Tos NetConpits ve aoe sna carpe 1 [leaner 2 Conver Creu Hy Engine Ol Terperaare Senor CutCY Sat Tet Tha Detect Vahl ota 1R iAberiod KOER . hject: Contiol roseure iulioe IR [EGR Tree Peston Sener Minin Sop TFN Supp Vetage Creut | FIN supp Netge Creut High I Syser Vstagn Ox F Se Tex Range EGR Flow Oa OF Sal Tost Reron Engh rol warn oughta ran KOED CCT aba Tes |e lal-Abre HOER COT ot [Crash toca mairinioed andar cp Basten ears eect lege pour ow [ICN dos oer [era utp eu chk agi Erbe ac war ci raking res, cr are, Iu ses Dated Pa24s, Dee, BP, PDEA Charging pte aut Vlg ca ih ew a ow i aria (AC Demand Ou OF Sa Tost Range Yi Spar Server Ut Ot Sa Ta OER Tas Ins lows vorertrenveearee crea dreebe rey JR Transratsion Ranga Cat Not nesting "Nav pak ang KOED ar KOER ‘Opa a EC la fly wane PENT outa ung Sef Te T Irouicert Srghs Speed Dezesse Ong Sl Tent RR ThrotlaPodal Postion SersavSwtan 0 Creu Low | ara Poin Sera CREATOR (PRATER SwsrSHNE Cato i © 10) ThraiaPedal Pantion SeraswSwich E Creu High now [pase c 0] ThowaPal PonlanSereaiS¥IOTF Gras Low rea I Thrtadal ition SoreaiSwich F Creat Hh I oaasa Poston SeresiSwi DE Vota \Coralaten 1 hatlamedal Postion SeranfSwich OF Velage (Carlsen I romseaa Postion SerSSISWICN ET VORDIAGNOSTIC CODES BLE eae TurborSuper Charger Boon Pressure not Detected Mechanical [Earalation betwaan IAT? and IAT are not at expaced values, No boost pressure Micrease was detected, [Gpanlehoriad crcum, Has sensor POM IMAP hose, MAP sensor, CAG system leaks, Imake leaks, EP sensor, exhaust restriction PRES TTurbe’Supar Charger System Patarmance IMAP Tose, MAP sensor, CAC system leaks, sensor, exhaust restriction, exhaust leaks, Drain wi reat inegriy Trlake Teale, EP PRA See diagnos Tania TOP syste Pea ioe isha lo ground or open, defective sensor Paz |e TP eres T. Wiat Or Voat, defective Sanson PEE jacior Ganirel Pressure Teo High [See diagnortc manual - ICP aysiern PIG joctor Control Pressure Toa High Engine OF od IGA, KOEO ICP i grater Than emp, feud open, detective Gar Ga jacior Control Pressure Too Low inferred [GP is aad, [OP fs below desea prewaure Peza jector Gantrol Pressure Too Lew - Engine [No start |OP is less than T25paVimpa, TOTS [Shock CANGAIGANEL circuits, POM, or FIM sue UOTES USO 10F-SERIES(SINGLE ALT.) Oy: o-@ ; t om, Or & woh. Tu h AlF-SERIES(SINGLE ALT.)F-SERIES(DUAL ALT.)F-SERIES(DUAL ALT.)ECONOLINE*(SINGLE ALT.)ECONOLINE*(SINGLE ALT.)ECONOLINE*(DUAL ALT.)