Help Needed. Cab is off. What should be done to booletproof the engine 100% ?

[Bikersmurf]

Ambulance packages come equipped with high output Alternators & or two. My 7.3 came with a 215 amp Mitsubishi (32 lb/14.5 kg monster)... they're good but getting harder to find. Newer ones switched to dual alternators, and in your case that's what I'd recommend. And as suggested I'd isolate the house batteries then add a kick-*** solenoid to connect house and starting batteries together for extra starting power (Sure-Start circuit).

 

[stormlover]

The factory alternators are quite high-output, so you shouldn't have any worries there.

Really? I'm not expert but most 6.0 owners consider the stock alternator woefully inadequate. Some interesting reading here:

The stock alternator puts out only 65 amps at hot idle and 100 amps when driving down the road at full operating temperature. It's the same part number used in the Ford Fusion!

source: http://www.ficmrepair.com/index.cfm/page/ptype=results/category_id=39/mode=cat/cat39.htm

With all the accessories that we put on and in our camper vans it makes sense to go with a higher output alternator. I went with the 250A XP from DCpower. https://www.dcpowerinc.com/fit/Ford~E-350~2005~6.0L-V8-Powerstroke-Diesel/8307-250-xp.html

 

[szooter]

Engine Manuals ?

Gents,

I have finally manage to order parts for my engine upgrade.
Tried few places but finally only Bulletproofdiesel will send it to Poland and I will tell you - Andrew from BPD is a great guy, big help!

This is a list of parts I have ordered based on expo and BPD advise

90201038
Head Gasket Install Complete Kit, 2006+ Ford 6.0L, Ford Head Gaskets 20mm Dowel
6000010 ARP Head Studs for Ford 6.0L Power Stroke Diesel
6000022 Head Gasket, 20mm, Ford 6.0L Diesel, Each, No Head Bolts or Stand Pipes Included
6000041 Rocker Carrier Gasket, Ford 6.0L
6000042 Fuel Injector O-Ring Kit
6000044 Teflon Sealing Washer, Sold in Packs of 6.
6000046 Ford 6.0L Coolant Thermostat
6000071 Oil Rail Dummy Plug, Ford 6.0L Diesel
6000081 Oil System Stand Pipe, 2004.25+, Ford 6.0L Diesel
90201099 Fan Clutch, Mechanical, with Bullet Proof Diesel Adapter
6000148 Fan Clutch, Mechanical, 1997 7.3L Ford Diesel
6502213 Fan Clutch Adapter, 6.0L to 7.3L Ford Diesel
90201049 2004.25-2007 Billet Water Pump Assembly - 100mm
6000033 Oil Pressure Switch, Ford 6.0L Diesel
6000034 High Pressure Oil Pump (HPOP) Connector Fitting Upgrade Kit, 2005-2007 F-Series, 2005-2010 E-Series
4C3Z-12A342-AA Glow Plugs
AC2Z-2A451-A Vacuum Pump
W300965 Glow Plug Harness O Ring
6000062 Ford 6.0L Diesel Fuel Injector, Late - Use VIN

90201081_BK Bullet Proof Diesel FICM Power Supply Upgrade - Black - 6-Phase - 4-Pin
6000049 Engine Oil Filter, Ford 6.0L Diesel, Factory Ford Part
6000116 Ford Fuel Filters for 6.0L E-Series Diesel
FA-1804 Ford Air Filter

I hope that together with already installed new turbo, new oil cooler and egr delete this should address all the weakness of the engine.

I have good mechanics to do the job and I will be helping with the upgrade, but we need some detailed good manuals as this will be first time working with the powerstroke for us

Can you gents advise which manual / manuals I need for the successful upgrade and where I can source them ?

My van is 2006 Ford E-350 Super Duty 6.0 diesel VIN:1FDNE31P96DA21849.

 

[thethePete]

Sounds like you'll have a happy motor after all that. Good choice, and I've got nothing but good things to say about BPD also. They really are top notch.

I believe there are personal use licenses for Mitchell and AllData, which are aftermarket technical references, they have adequate information to allow you to rebuild a 6.0. If you are willing to spring for it, the factory service manuals are available on ebay also, and nothing beats the OEM info.

 

[Sheep Shagger]

"W300965 Glow Plug Harness O Ring", I would forget those and buy the Glow Plug Harness, both sides ~$45 each side. Removing the glow plug harness without damage is almost imposible as it get's brittle with age. If you don't buy the harness, at least buy the $10 ford tool to try to pop-out the harness without damage.

4C2Z-9T517-AA. 6.0 Blue spring (fuel pressure regulator). The stock spring get's weak with age so Ford made an upgrade kit. It's a new spring (blue in color) a few O rings & bolts.

As for manuals, the complete ford E350 6.0 PSD set is all you need (3 books), it will talk you through everything in great detail. I paid $45 of ebay for my set.

"4C3Z-12A342-AA Glow Plugs" Are you sure you need them?, they are cheap @ $15 each so probably doesn't matter, but they seem to be bulletproof on the 6.0. It's the Glow Plug Harness & Glow Plug Control Module that break on the 6.0. So if you are running down Glow Plug error codes, I wouldn't directly think it's the actual glow plugs like you would on most diesels.

 

[thethePete]

^ Good adds Scotsman, I didn't look close enough at the list. I agree with getting the GP harnesses, it's just easier, and it will save you greif down the road. Same with the blue spring. I recommend that if nothing else to every 6.0 owner. Just did another customer last week, actually. Weakening spring and hardening o-rings aside, there's hardly enough headroom with the stock fuel pressure for the injectors to live a happy life anyway.

Fresh glowplugs are never a bad idea at this level of a rebuild anyway, you've come this far. No sense skipping on a $15 part to find out you dinked one in the rebuild process. They kinda suck to get at in a van in the engine bay. F-bodies aren't bad 'cause you just pull the fender liner.

 

[szooter]

Thanks Guys !

I will try to get the GP harnesses as well, shame the BPD package is already underway and I can't add to it ...
Shipping to my place is a real pain unfortunately ...

So another question - am I missing something else ? Do I need any special tools for replacing fuel injectors or I can do without it ? Any other special tools I really MUST have ?
I need to get everything together as I have the workshop booked in 2 weeks and with all this shipping time it is not gonna be easy if I miss something ...

For the blue spring Chris from Ujoint have changed it I think - updated fuel regulator spring - that is how I have it on the quote from Ujoint.

Chris if You read this can you please confirm that is that spring ?

As for the manuals I have sign up to Mitchell today - by brief look it looks OK, hope will do the job.

 

[thethePete]

Injectors bolt in, but make sure you torque them perfectly, or you'll have failures. You listed new ones? That makes it easier, although "rebuilding" them is a fairly straightforward ordeal, it's just a series of o-rings, and they're colour coded.

I think I recall Chris mentioning he does use the International blue-spring, if he lists it updated, you're good there.... hopefully he can chime in for sure, but I'm not aware of any other FPR spring.

Mitchell is pretty decent, I find it better for wiring diagrams than AllData, but I prefer AllData's database. Either one will have more than adequate information to get you through the rebuild and if you've never used either you won't have a bias anyway. Just be sure to pay attention to the torque specs for reassembly, and make sure you lube the rockers and basically anything else that contacts, I like to submerge my pushrods in oil so I know they are well lubed when I drop them in the engine. I just put them in a bucket for a second before dropping them into the engine. The oil cooler will come with instructions for the rebuild. It's a lot of parts, but it's just a series of o-rings. Whenever you change an o-ring, take the old one and throw it on the floor, it will keep you from mixing them up or forgetting any. Do them one at a time. It's not hard, but there are a lot of opportunities for error.

Good luck. The job pays 26h or so by the book, and that's assuming you're a professional, with a full toolset. So don't feel overwhelmed, it's gonna take a while. This ain't no 350 Chev.

 

[szooter]

Thanks Guys for replies.
Pete i found your posts very informative - cheers !

I finally found some time to research a bit and it seems that it would be a good idea to change the Nipple Cups/Ball Tubes or at least change the gaskets on them together with the injectors
What are you guys think about those:
http://www.ebay.pl/itm/121963402628...c51372a5506&bu=44264569884&cp=1&sojTags=bu=bu
anybody tested it ? Worth the money ? Shall I go for it ?

i have also found those on ebay :
http://www.ebay.com/itm/6-0-6-0L-Po...ash=item35e884613d:g:TjgAAOSwv-NWazo9&vxp=mtr

Or maybe I should just purchase the gaskets ? If yes which would be the recommended ones ?

This thread I found is pretty good explaining the issue with the Nipple Cups/Ball Tubes
http://www.powerstroke.org/forum/ge...p-fuel-injector-seals-nipple-cup-o-rings.html

maybe I am going a bit to far, as I did not have any hot start issues yet.
But considering my engine is 200k already I want to do everything now to enjoy in the later stage, I am ready to invest now to have a piece of mind ...

I have also listed following Items on my list:

- Ford Motorcraft 6.0L Powerstroke IPR Injector Pressure Regulator & Install Tool
- 04.5-10 Ford 6.0 6.0L Powerstroke Diesel ICP Injector Control Sensor & Pigtail
- 04+ 6.0L Powerstroke Diesel OEM Motorcraft Glow Plug Harness & Module & Tool

I know I might be changing good parts but I will treat the old parts as ready to go spares on my shelve in emergency.

Any hints, insights ?

 

[thethePete]

I think you'll be fine with the existing nipple cups. I've rebuilt a lot of high mileage engines and not replaced them, as long as they feel snug pressing into the injectors you should be fine. If you want to replace them, just be diligent when torquing everything. As long as you're putting in the updated standpipes and dummy plugs you should be fine for HPO issues.

I wouldn't worry about changing the ICP pigtail unless it has visible damage or oil contamination. The tool is a good idea, but you might be able to get it from a 3rd party for cheaper. I think the one I have in my box is SK? Either way, lots of places make them and they're around 30-50$?

As far as injector stuff, go with OEM, or Alliance Power. Uptime makes good aftermarket injectors, but I still recommend OEM ones.

Glow plug harness is a good idea since they get brittle and they're cheap. The tool makes life easier. If you get stuck anywhere along the road I'll try to help where I can.