6.0l—hard start / long crank / no start—tsb 08...

6.0L—HARD START / LONG CRANK / NO START— TSB 08-18-6LOW INJECTOR CONTROL PRESSURE (ICP)

2005-2007 F-Super DutyFORD:2005-2008 E-350, E-450

2005 Excursion

This article supersedes TSBs 08-9-9 and 05-12-3 to b. If DTCs P2290 and/or P2291 are presentupdate the Service Procedure and Service Labor proceed to the ICP Graph Comparison Test.Times.

c. If DTCs other than P2623, P2290 and/orP2291 are present refer to PC/ED, and doISSUEnot continue with this procedure.Some 2005-2007 F-Super Duty, 2005-2008 E-Series

and 2005 Excursion vehicles equipped with a 6.0L d. If no DTCs are present proceed to the ICPdiesel engine may exhibit a hard start / long crank Graph Comparison Test.or no start condition due to low injection controlpressure (ICP). ICP Graph Comparison Test

NOTEACTIONBATTERIES MUST BE FULLY CHARGED BEFOREFollow the Service Procedure steps to correct thePROCEEDING.condition.

If oil is leaking from the ICP system or if air isSERVICE PROCEDUREtrapped in the ICP system, the injection pressure

NOTE regulator (IPR) valve may be commanded fullyA FLOW CHART OF THIS PROCEDURE CAN BE closed by the Powertrain control module (PCM)FOUND AT THE END OF THIS ARTICLE. while the starter is engaged in an attempt to exceed(FIGURES 13-16) 500 psi (3.5 MPa).

NOTE 1. Select the parameters indicated from the scanTHE LOW PRESSURE OIL SYSTEM MUST BE tool parameter list.WORKING PROPERLY IN ORDER FOR THE HIGH

a. ICP Pressure + Voltage.PRESSURE OIL SYSTEM TO BUILD ICPPRESSURE. THIS INCLUDES ADEQUATE BASE b. IPR Duty Cycle.ENGINE OIL SUPPLY PRESSURE AND GOODQUALITY PROPERLY MAINTAINED OIL. THIS c. Engine Speed (RPM).MUST BE VALIDATED BEFORE CONTINUING

2. ICP pressure should reach 500 psi (3.5 MPa)WITH THIS PROCEDURE.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

a. Normal start response for ICP, IPR Duty(KOEO) for bias: If voltage is not between 0.15Cycle and Engine Speed - Operation shown.V and 0.35 V refer to Powertrain(Figure 1)Controls/Emissions Diagnosis (PC/ED), and do

not continue with this procedure.

2. Check for diagnostic trouble codes (DTCs).

a. If DTC P2623 is present go to pinpoint testR in PC/ED before continuing to the ICPGraph Comparison Test.

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to dothe job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in propervehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact aFord, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentationdetermine 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 isavailable through Ford Motor Company’s on-line technical resources.

Copyright 2008 Ford Motor Company Online Publication Date August 28, 2008 PAGE 1

TSB 08-18-6 (Continued)

Figure 1 - Article 08-18-6

b. Hard start response for ICP, IPR Duty Cycleand Engine Speed - Operation shown.(Figure 2)


c. No start response for ICP, IPR Duty Cycleand Engine Speed - Operation shown.(Figure 3)

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3. 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,

a. If the engine starts and the IPR has beenrefer to PC/ED for no start diagnosis, andreplaced proceed to Step 7.do not continue with this procedure.

b. If the IPR has not been replaced drive theb. If the ICP PID data is within specification,vehicle and monitor the engine oil(Figure 2 ) and the engine starts, drive thetemperature using IDS until the EOTvehicle and monitor the engine oilreaches 195 °F (91 °C). Turn off engine andtemperature using IDS until the engine oilproceed to Step 6.temperature (EOT) reaches 195 °F (91 °C).

Proceed to Step 4. c. If the engine will not start, proceed to theAir Pressure Test (ICP) procedure. Refer toc. If the ICP PID data is not withinappropriate vehicle.specifications, (Figures 2 or 3), proceed to

Step 5. 6. If the engine starts with EOT at 195 °F (91 °C)perform a run up test by a slow neutral run up4. With engine oil temperature (EOT) at 195 °Fin park/neutral. Does the engine run rough(91 °C). Crank the engine and recheck the ICPbetween 3000 and 4000 RPM?PID data.

a. If the engine runs rough replace the IPRa. If repairs were performed and the ICP PIDvalve. Proceed to Step 7.data is within specification, (Figure. 1),

release the vehicle to the customer. b. If the engine does not run rough, proceed tothe 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 therefer 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 ac. 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 40003), proceed to Step 6. RPM?

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a. If the engine runs rough proceed to the AirPressure Test (ICP) procedure.

b. If the engine does not run rough crank theengine and recheck the ICP PID data.

(1) If the ICP PID data is withinspecification, (Figure 1), release thevehicle to the customer.

(2) If the ICP PID data is not withinspecification, (Figure 1), proceed to theAir Pressure Test (ICP) procedure.

Air Pressure Test ICP

Figure 4 - Article 08-18-6NOTEBEFORE PERFORMING THIS TEST, INSPECT 3. Install test adapter 303-765 in the top of theTHE O-RINGS OF THE TEST TOOLS. REPLACE high-pressure oil pump. Attach shop air hose toIF WORN, CRACKED OR CUT. the test adapter. (Figure 4)

NOTE 4. Apply shop air at 100 psi (689 kPa) maximumTHE AIR PRESSURE APPLIED FOR THIS TEST to the high-pressure oil pump.MUST BE 100 PSI (689 kPa). WHEN AIR

5. Using IDS, command IPR open for two (2)PRESSURE IS APPLIED FOR THE FIRST TIME,minutes to clear the oil from the high pressureIT MAY TAKE 3 TO 5 MINUTES BEFORE THEoil system.LEAK CAN BE HEARD. THIS ALLOWS THE AIR

PRESSURE TO DISPLACE THE ENGINE OIL IN6. Using IDS close the IPR valve by increasing

THE ICP SYSTEM. ONCE THE ENGINE OIL ISthe IPR duty cycle. If no air noise change is

DISPLACED, AN AIR LEAK CAN BE HEARDheard, the IPR valve may not be functioning as

ALMOST IMMEDIATELY AFTER APPLYING AIRcommanded. If the IPR has been replaced

PRESSURE.proceed to Step 9. If the IPR has not beenreplaced in a previous repair install a new IPRCAUTIONvalve and perform a slow neutral run up inDO NOT LEAVE THE IPR VALVE ENERGIZEDpark/neutral.LONGER THAN 120 SECONDS. THIS CAN

DAMAGE THE IPR VALVE a. If the engine will not start repeat the AirPressure Test (ICP) procedure. Econoline

b. If the engine runs rough between 3000 and1. Remove the engine cover; refer to Work Shop4000 RPM repeat the Air Pressure TestManual (WSM), Section 501-05.(ICP) procedure.

2. Remove M 12 plug from the top of thec. If engine does not run rough between 3000high-pressure oil pump. (Figure 4)

and 4000 RPM, Crank the engine andrecheck 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 withinspecification, (Figure 1), start and drive thevehicle, monitor the engine oil temperatureusing IDS until the EOT reaches 195 °F (91°C).

8. With EOT at 195 °F (91 °C), crank the engineand recheck the ICP graph comparison test.

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a. If repairs were performed and if the ICP PID NOTEdata is within specification, (Figure 1), A PIECE OF HOSE THAT WILL FIT DOWN INTOrelease the vehicle to the customer. THE OIL FILL STAND TUBE MAY BE NEEDED TO

AID IN DETECTING AIR LEAKS IN THEb. 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 KPAPressure Test (ICP) procedure in this article. (100 PSI). WHEN AIR PRESSURE IS APPLIED

FOR THE FIRST TIME, IT MAY TAKE 3 TO 59. Listen for an air leak. If a no start or hard startMINUTES BEFORE THE LEAK CAN BE HEARD.condition exists, an audible leak may beTHIS ALLOWS THE AIR PRESSURE TOidentified by using a stethoscope through the oilDISPLACE THE ENGINE OIL IN THE ICPfill tube or left valve cover crankcase vent holeSYSTEM. ONCE THE ENGINE OIL ISor by listening at the rear of the engine.DISPLACED, AN AIR LEAK CAN BE HEARD

10. If the leak is isolated to the back of the engine, ALMOST IMMEDIATELY AFTER APPLYING AIRgo to Replace Snap To Connect (STC) PRESSURE.procedure.

3. Connect the shop air supply line to the ICP11. 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 HighPressure Oil Pump Test procedure.

F-Super Duty And Excursion

1. Remove the ICP sensor from the right sidevalve cover. Refer to WSM, Section 303-04C.Install the ICP system test adaptor 303-765 inthe threaded cavity where the ICP sensor waslocated. (Figure 5)


NOTEAN AIR LEAK SHOULD BE HEARD AT THISTIME. AIR SHOULD BE PASSING THROUGH THEIPR VALVE AND RETURNING TO THECRANKCASE WHEN THE IPR VALVE IS NOTENERGIZED.

4. Using IDS, command IPR open for two (2)minutes to clear the oil from the high pressureoil system.

Figure 5 - Article 08-18-65. Using IDS, close the IPR valve by increasing

2. Remove the oil fill cap from the valve cover.the IPR duty cycle.

a. If no air noise change is heard, the IPRvalve may not be functioning ascommanded.

b. If the IPR has been replaced proceed toStep 8.

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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 303-04C.perform a slow neutral run up in

NOTEpark/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 PressureNOTETest (ICP) procedure.IF THE HIGH-PRESSURE OIL PUMP AND

(3) If engine does not run rough between BRANCH TUBE ADAPTER HAS AN ASSEMBLY3000 and 4000 RPM, crank the engine SUPPORT BRACKET, REMOVE AND DISCARDand recheck the ICP comparison test. THE ASSEMBLY SUPPORT, AND ALL

ATTACHING HARDWARE. THIS WILL NOT BE6. 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 tubespecification , (Figure 1), start and drive the adapter and STC or jam nut fitting from thevehicle, monitor the engine oil temperature high-pressure oil pump. Discard either type ofusing 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 ICPPID data.

a. If repairs were performed and if the ICP PIDdata is within specification, (Figure 1),release the vehicle to the customer.

b. If the ICP PID data is not withinspecification, (Figure 1), repeat the AirPressure Test (ICP) procedure in this article.

8. Listen for an air leak. If a no start or hard startcondition exists, an audible leak may beidentified by using a stethoscope through the oilfill tube or left valve cover crankcase vent hole

Figure 7 - Article 08-18-6or by listening at the rear of the engine.

NOTE9. If the leak is isolated to the back of the engine,IT IS NOT NECESSARY TO REPLACE THE HIGHproceed to replace STC procedure.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.

CAUTION11. 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 WRONGLOCATION.NOTE

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 cleanNOT AN INDICATION OF A HIGH PRESSURE OIL engine oil, rotate the jam nut clockwise to theLEAK AND THE HIGH PRESSURE OIL PUMP base of the branch tube adapter. The adapterSHOULD NOT BE REPLACED FOR THIS is threaded to the jam nut. (Figure 8)CONDITION.

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Figure 8 - Article 08-18-6 Figure 10 - Article 08-18-6

CAUTIONTHE BRANCH TUBE ADAPTER MUST BEINSTALLED AT THE CORRECT DEPTH TOPREVENT HIGH PRESSURE OIL LEAKS.

6. Install the branch tube adapter into thehigh-pressure oil pump by threading it five (5)complete turns to set proper depth and setproper orientation. Tighten the jam nut to seatthe O-ring at this time. (Figure 9)


8. With plastic holding tool securely fastened,torque jam nut to 49 lb-ft (66 N•m) with a 15/16crow foot open end wrench and torque wrench.

NOTETORQUE SPECIFICATION FOR STEP 8 ISCALCULATED FOR THE USE OF A CROW FOOTOPEN END WRENCH.

9. Remove and discard holding tool, plastic boltsFigure 9 - Article 08-18-6and wing nuts.

CAUTION10. Install the new dowel pin provided in kit.TO PREVENT ENGINE DAMAGE, BRANCH TUBE

ADAPTER OIL OUTLET HOLE MUST FACE 11. Lubricate and install a new O-ring in the branchDOWN. tube inlet recess and in the high-pressure oil

pump inlet recess.7. Loosen the jam nut 1/4 turn. Install holding toolusing the supplied plastic bolts and wing nuts CAUTIONto align and position the jam nut fitting. (Figures TO PREVENT ENGINE DAMAGE THE OIL10 and 11) SUPPLY HOLE IN THE BRANCH TUBE

ADAPTER MUST FACE THE BRANCH TUBEASSEMBLY.

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12. Install the high-pressure oil pump with branch NOTEtube adapter already installed. Use new bolts BEFORE PERFORMING TEST PLACE THEsupplied in kit. Finger tighten the three (3) M TURBOCHARGER OIL FEED TUBE INTO A8x45 bolts securing the high-pressure oil pump SUITABLE CONTAINER TO CATCH THE ENGINEto the crankcase and the two (2) M 6x30 bolts OIL.holding the branch tube adapter to the branch

3. Disconnect the fuel injector control moduletube.(FICM) relay.

NOTE4. Crank the engine to prime the oil system.NOTICE BRANCH TUBE ADAPTER TO BRANCH

TUBE HOLE MISALIGNMENT IN MOST CASES 5. Repeat Air Pressure Test (ICP).THERE IS ENOUGH CLEARANCE IN THEBRANCH TUBE ASSEMBLY AND a. If no leaks are found, reconnect the FICMHIGH-PRESSURE OIL PUMP ASSEMBLY FOR relay, check engine oil level, and refill asPROPER HOLE ALIGNMENT. IF UNABLE, TO required. Return to customer.ALIGN HOLES THE BRANCH TUBE ASSEMBLY

b. If leaks are found, proceed to Step 6.WILL HAVE TO BE REPLACED. (FIGURE 12)

6. Remove and discard M 12 plug from the top ofthe high-pressure oil pump. (Figure 4)

7. Install ICP system test adaptor 303-765 in thetop of the high-pressure oil pump. Attach shopair hose to the test adaptor. (Figure 5)

8. Apply shop air at 100 psi (689 kPa) maximumto 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 andinstall the new M 12 plug provided in service

Figure 12 - Article 08-18-6 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 theand refill as required. Return to customer.

high-pressure oil pump to the crankcase to 23lb-ft (31 N•m) 12. If a leak is identified in the branch tube, use

the Branch Tube Replacement Procedure for14. Tighten two (2) M 6x30 bolts that hold the

F-Super Duty and Excursion. Econoline refer tobranch tube adapter jam nut to branch tube to

WSM, Section 303-01C.97 lb-in (11 N•m). Pressure test to verify repairand 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 Mpresent. 12 plug provided in service kit. Tighten M 12

plug to 26 lb-ft (36 N•m) and go to Under ValveAir Pressure Testing (Pump) - After STC

Cover Leak Test procedure.Replacement

High Pressure Oil Pump Test - No Audible Air1. Remove the ICP adapter 303-765 from the ICP

Leakport, 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.

Refer to WSM, Section 303-01.2. Install IPR valve.

2. Remove both upper crankcase to head tubes(stand pipes).

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3. Install the fuel rail block off tool 303-1163/2, Under Valve Cover Leak Test (Air Leakinto the rear of the left high pressure oil rail Detected)where the upper stand pipe was removed.

NOTE4. Remove the ICP sensor. BEFORE PERFORMING THIS TEST, INSPECT

THE O-RINGS OF THE TEST TOOLS. REPLACE5. Install the ICP sensor into the block off tool IF WORN, CRACKED OR CUT.

303-1163/1 into the rear of the right highpressure oil rail where the upper stand pipe 1. If not removed previously, remove the left andwas removed. right hand valve covers. Refer to WSM, Section

303-01.6. 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 highharness is unavailable, proceed to Alternate pressure oil rail and install the ICP system testHigh Pressure Oil Pump Output Test procedure. adaptor 303-765 in the threaded cavity where

the ICP sensor was located.7. Disconnect the FICM relay.

3. Apply 100 psi (689 KPa) regulated shop air8. Crank the engine while monitoring the ICP PID, pressure.

Pressure should reach a peak of a minimum1500 psi (10.5 MPa). 4. Key on, engine off. Using the scan tool,

command the IPR valve closed by increasing9. 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 pressureCover Leak Test procedure. oil rails. If leaks are found repair as necessary.

Alternate High Pressure Oil Pump Output Test - Branch Tube Replacement For F-Super DutyIf Jumper Harness 418-D003 (D94T-50-A) And Excursion Vehicles OnlyUnavailable

1. Remove the transmission, see the appropriateNOTE model year WSM, Section 307-01.BEFORE PERFORMING THIS TEST, INSPECTTHE O-RINGS OF THE TEST TOOLS. REPLACE NOTEIF WORN, CRACKED OR CUT. LEAVE THE FLYWHEEL ON, IT WILL MAKE IT

EASIER TO TURN THE ENGINE OVER TO TOP1. Remove the left and right hand valve covers. DEAD CENTER (TDC), THE TRANSMISSION

Refer to WSM, Section 303-01. FLUID DOES NOT NEED TO BE DRAINED.

2. Remove the left upper crankcase to head tube 2. Set engine at TDC (both cylinder number 1(stand pipe) and install the oil rail block off tool rocker arms should be loose) (See rocker arm303-1163/2 into the rear of the left high removal procedure in the appropriate onlinepressure oil rail. WSM, Section 303-01C).

3. Install the ICP sensor and connect. 3. Remove the right and left side high-pressure oilrails.4. Disconnect the FICM relay.

4. Remove and inspect both high-pressure5. Crank the engine while monitoring ICP PID.standpipes for D-ring wear or stand pipePressure should reach a peak of a minimum ofdamage. If damaged replace stand pipe(s).1500 psi (10.5 MPa).

5. Remove the port plugs and inspect for damage,6. If a peak of a minimum of 1500 psi (10.5 MPa)if damaged replace the port plugs. Refer tois not reached, replace the high pressure pump.(Figure 12)

7. If pressure is OK, go to Under Valve Cover6. Remove fuel injectors from cylinders 6, 7 andLeak Test procedure.

8. (WSM, Section 303-04C, use Ford SpecialService Tool Number 303-1115)

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7. Inspect all injectors for D-ring and/or snap-ring 14. Insert a 10″ long 1/4″ locking extension with adamage at the injector to high pressure oil rail T27 locking Torx bit through cylinder number 7plug location. exhaust push rod hole and loosen the hold

down bolt. Use a magnet through the standpipe8. 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 vehicleexhaust rocker arms from cylinders number 7 watch from the rear cover area to guide theand number 8 then remove the push rods (See socket on the bolt head of the branch tube holdWSM, Section 303-01C, use Ford special down).service tool number 303-1170. The rocker armplastic retaining clips may break upon removal. NOTEMake sure all the pieces are removed from the THE BOLT HEAD IS NOT VISIBLE ON THIS SIDE.head).

CAUTION9. Rotate engine one (1) full revolution, see WSM, IF THE TORX BIT IS DROPPED IT WILL BE

Section 303-01C rocker arm removal procedure. NECESSARY TO REMOVE THE CYLINDER HEADTO RETRIEVE IT.

10. Remove exhaust rocker arm from cylindernumber 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

303-01C. Cut the sealant at the rear cover “T” 16. Pack the branch tube bolt holes with greasejoints for the bedplate gaskets and and install retaining bolts in the branch tubehigh-pressure pump cover gasket before fully flush with the bottom.removing.

17. If the high pressure pump was removed itNOTE needs to be installed at this point. Torque theUSE A LONG PUTTY KNIFE OR RAZOR BLADE mounting bolts to 26 lb-ft (35 N•m).TO SEPARATE THE BED PLATE GASKETS TO

18. Install the two (2) 8 mm bolts into the branchPREVENT DAMAGE. DO NOT STRETCH THEtube adapter.BEDPLATE GASKETS OR THE BEDPLATE WILL

HAVE TO BE REMOVED. 19. Install a new high-pressure oil branch tube intothe block. Start the two (2) 8 mm bolts from the12. Loosen the two (2) 8 mm bolts that hold thedischarge tube into the branch tube. Havebranch tube adapter to the branch tube. (Usesomeone under vehicle guide and start the holdopen end / box end wrench - thin)down bolts through cylinder 7 and cylinder 6

13. Insert a 10″ long 1/4″ locking extension with a push rod holes. While tightening the branchT27 locking Torx bit through cylinder number 6 tube hold down bolts maintain positive outwardexhaust push rod hole. Use a magnet through pressure on the branch tube. Torque thethe 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,

20. Tighten the two (2) 8 mm discharge tube bolts.have someone under the vehicle watch fromTorque to 11 lb-ft (15 N•m).the rear cover area to guide the socket on the

bolt head of the branch tube hold down). 21. Clean the rear engine cover. Install a newgasket. Add Motorcraft Ultra Silicone SealantCAUTIONto the bedplate and the high pressure pumpIF THE TORX BIT IS DROPPED IT WILL BEcovers joints. Install the rear engine cover.NECESSARY TO REMOVE THE CYLINDER HEADTorque to 18 lb-ft (24 N•m).TO RETRIEVE IT.

22. Install a new rear main seal using Ford SpecialService Tool Number 303-770.

23. Install rear main seal dust cover.

24. Install the flywheel.

NOTENEW FLYWHEEL BOLTS REQUIRED.

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25. Install the starter. OPERATION DESCRIPTION TIME081806A 2005-2007 Super Duty, 1.0 Hr.

26. Install push rod and rocker arm in cylinder 2005 Excursion (6.0L)number 6. Time Includes: Checking

DTCs and ICP voltage;27. Rotate engine 1 full revolution.ICP Graph Comparison

28. Install push rods and rocker arms in cylinders Test(s); Pin Point Test Rnumber 7 and number 8. and Road Test. This Labor

Operation Can Only Be29. Install the upper and lower crankcase to head Claimed With Operation B.

tubes (stand pipes), replace if damaged. (Do Not Use With AnyLabor Operations Outside30. Install fuel injectors.Of This TSB)

31. Install high-pressure oil rails, per WSM, Section 081806A 2005-2008 Econoline 1.1 Hrs.303-04C. (6.0L) Time Includes:

Checking DTCs and ICP32. Install the valve covers. voltage; ICP Graph

Comparison Test(s);33. Install the (FICM).Removing Engine Cover;

34. Install the air filter housing. Pin Point Test R and RoadTest. This Labor Operation

35. Install coolant overflow tank. Can Only Be Claimed WithOperation B. (Do Not Use36. Install right side charge air cooler (CAC) tube.With Any Labor Operations(Hot Side)Outside Of This TSB)

37. Install the transmission, see the appropriate 081806B 2005-2007 Super Duty, 1.3 Hrs.model year WSM, Section 307-01. 2005 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 OfThe Labor Operations In

PART NUMBER PART NAMEThis Article. (Do Not Use

4C3Z-9B246-C ICP Fitting Kit With Any Labor Operations5C3Z-9J332-C Branch Tube Outside Of This TSB)3C3Z-6379-BA Flywheel Bolt (Automatic

081806B 2005-2008 Econoline 0.7 Hr.Transmission-10 per repair required)(6.0L): Replace The IPR3C3Z-6379-CA Flywheel Bolt (Manual-10 per repair

required) Valve. This LaborTA-29 Motorcraft Ultra Silicone Sealant Operation Can Be Claimed

With Any Of The LaborWARRANTY STATUS: Eligible Under Provisions Of Operations In This Article.

New Vehicle Limited (Do Not Use With AnyWarranty Coverage Labor Operations OutsideIMPORTANT: Warranty Of This TSB)coverage limits/policies arenot altered by a TSB.Warranty coverage limitsare determined by theidentified causal part.

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081806C 2005-2007 Super Duty, 1.8 Hrs. 081806D 2005-2008 Econoline 4.5 Hrs.2005 Excursion (6.0L) (6.0L) Time Includes:Time Includes: Checking Replacing STC And/OrDTCs and ICP Voltage; High Pressure Pump;ICP Graph Comparison Perform Air Pressure TestTest(s); Pin Point Test R; At Test Port On High3-4000 RPM Run Up Pressure Oil Pump. ThisTest(s); Air Pressure Labor Operation Must BeTest(s) at ICP Port and Claimed With Operation C;Road Tests. This Labor Can Be Claimed With BOperation Can Be Claimed And Either E Or F. (DoWith Any Of The Labor Not Use With Any LaborOperations In This TSB Operations Outside Of ThisExcept A. (Do Not Use TSB)With Any Labor Operations 081806E 2005-2007 Super Duty, 10.8Outside Of This TSB) 2005 Excursion (6.0L 4X4 Hrs.

081806C 2005-2008 Econoline 2.0 Hrs. Automatic Transmission)(6.0L) Time Includes: Time Includes: ReplacingChecking DTCs and ICP Branch Tube; Inspect: AllVoltage; ICP Graph Injectors, Port PlugComparison Test(s); D-rings, Standpipes andRemoving Engine Cover; Replace as Necessary.Pin Point Test R; 3-4 This Labor Operation Must000RPM Run Up Test(s); Be Claimed With OperationAir Pressure Test(s) at C and D; Can Also BeHigh Pressure Pump and Claimed with B. (Do NotRoad Tests. This Labor Use With Any LaborOperation Can Be Claimed Operations Outside Of ThisWith Any Of The Labor TSB)Operations In This TSB 081806E 2005-2007 Super Duty, 10.0Except A. (Do Not Use 2005 Excursion (6.0L 4X2 Hrs.With Any Labor Operations Automatic Transmission)Outside Of This TSB) Time Includes: Replacing

081806D 2005-2007 Super Duty, 4.9 Hrs. Branch Tube; Inspect: All2005 Excursion (6.0L) Injectors, Port PlugTime Includes: Replacing D-rings, Standpipes andSTC And/Or High Pressure Replace as Necessary.Pump; Perform Air This Labor Operation MustPressure Test At ICP Port Be Claimed With Operationand Air Pressure Test At C and D; Can Also BeTest Port on High Claimed with B. (Do NotPressure Oil Pump. This Use With Any LaborLabor Operation Must Be Operations Outside Of ThisClaimed With Operation C; TSB)Can Be Claimed With BAnd Either E Or F. (DoNot Use With Any LaborOperations Outside Of ThisTSB)

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081806E 2005-2007 Super Duty 10.4 081806F 2005-2007 Super Duty, 4.2 Hrs.(6.0L 4X4 Manual Hrs. 2005 Excursion (6.0L):Transmission) Time Remove Valve Covers andIncludes: Replacing Branch Perform Under ValveTube; Inspect: All Injectors, Cover Leak Test, TimePort Plug D-rings, Includes Removing andStandpipes and Replace Inspecting: High Pressureas Necessary. This Labor Oil Rails, D-Rings,Operation Must Be Standpipes, Injectors AndClaimed With Operation C Replace as Necessary.and D; Can Also Be This Labor Operation MustClaimed with B. (Do Not Be Claimed With OperationUse With Any Labor C; Can Also Be ClaimedOperations Outside Of This with B and D. (Do Not UseTSB) With Any Labor Operations

081806E 2005-2007 Super Duty 8.9 Hrs. Outside Of This TSB)(6.0L 4X2 Manual 081806F 2005-2008 Econoline 7.8 Hrs.Transmission) Time (6.0L): Remove ValveIncludes: Replacing Branch Covers and Perform UnderTube; Inspect: All Injectors, Valve Cover Leak Test,Port Plug D-rings, Time Includes RemovingStandpipes and Replace and Inspecting: Highas Necessary. This Labor Pressure Oil Rails,Operation Must Be D-Rings, Standpipes,Claimed With Operation C Injectors, And Replace asand D; Can Also Be Necessary. This LaborClaimed with B. (Do Not Operation Must BeUse With Any Labor Claimed With Operation C;Operations Outside Of This Can Also Be Claimed withTSB) B and D. (Do Not Use

081806E 2005-2008 Econoline 18.0 With Any Labor Operations(6.0L) Time Includes: Hrs. Outside Of This TSB)Replacing Branch Tube; 081806G 2005-2007 Super Duty, 2.9 Hrs.Inspect: All Injectors, Port 2005 Excursion (6.0L):Plug D-rings, Standpipes Perform High PressureAnd Replace as Pump Test, Time IncludesNecessary. This Labor Removing and InstallingOperation Must Be Valve Covers. This LaborClaimed With Operation C Operation Must Beand D; Can Also Be Claimed With Operation C;Claimed with B. (Do Not Can Be Claimed WithUse With Any Labor either Operations D Or HOperations Outside Of This and B. (Do Not Use WithTSB) Any Labor Operations

Outside Of This TSB)

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081806G 2005-2008 Econoline 5.7 Hrs. 081806H 2005-2008 Econoline 2.7 Hrs.(6.0L): Perform High (6.0L): Perform UnderPressure Pump Test, Time Valve Cover Leak TestIncludes Removing and with Valve CoversInstalling Valve Covers. Previously Removed.This Labor Operation Must Time Includes RemovingBe Claimed With Operation and Inspecting: HighC; Can Be Claimed With Pressure Oil Rails,either Operations D Or H D-Rings, Standpipes,and B. (Do Not Use With Injectors And Replace asAny Labor Operations Necessary. This LaborOutside Of This TSB) Operation Must Be

081806H 2005-2007 Super Duty, 1.7 Hrs. Claimed With Operation C2005 Excursion (6.0L): and G; Can be claimedPerform Under Valve with operation B. (Do NotCover Leak Test with Use With Any LaborValve Covers Previously Operations Outside Of ThisRemoved. Time Includes TSB)Removing and Inspecting: DEALER CODINGHigh Pressure Oil Rails, CONDITIOND-Rings, Standpipes, BASIC PART NO. CODEInjectors And Replace as 9B246 42Necessary. This LaborOperation Must BeClaimed With Operation Cand G; Can be claimedwith operation B. (Do NotUse With Any LaborOperations Outside Of ThisTSB)

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6.0l—hard start / long crank / no start—tsb 08...

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