Fuel Charging & Controls - 6.0l Diesel -- e350 & e450 Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Fuel System

The fuel system used on the 6.0L direct injection (DI) turbo diesel engine is controlled by the powertrain control module (PCM).

The fuel system components consist of

1. electric fuel pump.
2. high-pressure oil pump.
3. fuel filters.
4. injection pressure regulator valve.
5. injection control pressure (ICP) sensor.
6. fuel pressure regulator.
7. water in fuel switch/fuel heater thermostat.
8. fuel injection control module (FICM).

Fuel to be supplied to the combustion chambers passes through the fuel-conditioning module into the secondary fuel filter, then to the cylinder head galleries and then through the electrohydraulic injectors.

Excess fuel not used by the engine bypasses the secondary fuel filter, flows through the fuel pressure regulator assembly and returns to the fuel conditioning module.

Fuel Pump

The fuel pump is mounted in the fuel-conditioning module mounted on the LH frame rail. For additional information, refer to FUEL TANK & LINES .

Fuel Injectors

The engine uses an electrohydraulic injector as part of its fuel system. This PCM/FICM-controlled injector uses high-pressure lube oil to provide the necessary force to inject fuel into the combustion chamber at pressures up to 144 mPa (21,000 psi) at rated horsepower.

The injector fits into a sleeved bore machined into the cylinder head. The injector bore intersects with a machined fuel passage that runs the length of the head. Each injector has two O-ring seals around the outer body, one above the fuel passage and one below. A fuel inlet port between the O-ring seals allows fuel under pressure to enter the pressure amplification area of the injector. High-pressure engine oil enters the injector through the top. The high-pressure oil rail assembly is mounted on top of the fuel injector.

Scheme 57

Fuel Pressure Regulator

Fuel pressure in the cylinder head fuel galleries is controlled by a fuel pressure regulator. The fixed orifice is an air bleed in the fuel filter housing. It is the highest point in the fuel system. It allows the air behind the fuel pressure regulator to be vented to the fuel tank rather than ingested in the fuel galleries. The fuel pressure regulator contains a spring-loaded poppet valve, which opens to allow excess fuel to return to the fuel-conditioning module. Once back to the fuel-conditioning module, the fuel is sent back to the fuel tank or to the engine, if the fuel-conditioning module is in recirculation mode.

Scheme 58

Injection Control Pressure System

Fuel injection pressure is controlled by the injection control pressure (ICP) system. The ICP system consists of the following

1. ICP sensor mounted in the right valve cover.
2. injection pressure regulator valve located in the high-pressure pump.
3. powertrain control module.
4. high-pressure oil pump.

Fuel Charging and Controls

See INTRODUCTION -- 6.0L DIESEL article.

Special Tool(s)

SPECIAL TOOL Release Tool, Injector Release 303-1115

Material

MATERIAL SPECIFICATION

Scheme 59

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Remove the valve covers. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Disconnect the fuel injector electrical connector.
3. Loosen the crankcase-to-head tube assembly.
4. Position the crankcase-to-head tube and separate the tube. Allow the lower section to go back down. Remove and discard the D-ring seals.
5. Remove the bolts and the high-pressure oil rail.
6. Remove the crankcase-to-head tube. Remove and discard the D-ring seals.
7. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube. Remove and discard the D-ring seal.
8. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
9. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
10. Remove the bolt, fuel injector hold-down clamp and fuel injector.

Scheme 64

Scheme 65

Scheme 66

1. Install new D-ring seals on each end of the crankcase-to-head tube assemblies.
2. Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
3. Install the fuel injector, fuel injector hold-down clamp and bolt.
4. Remove the shop towels.
5. Install the fuel injector electrical connector into the rocker carrier.
6. Apply engine oil to the top fuel injector O-ring seals.
7. Apply clean engine oil on the crankcase-to-head tube D-ring seals and install the tubes.
8. Position the lower section of the crankcase-to-head tube in the engine.
9. Position the oil rail on the fuel injectors. Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle. Insert three guide bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the rail. Install the guide studs six to seven turns. Press the oil rail into the fuel injectors. Make sure that the oil rail mounting feet are flat against the mounting surface. Loosely install the six bolts.
10. Install the oil rail retaining bolts. Remove the three guide bolts. Loosely install three remaining bolts. Tighten the nine bolts in the sequence (Scheme 74)
11. Install the upper section of the crankcase-to-head tube.
12. Connect the fuel injector electrical connector.
13. Install the valve covers. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450).

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

Scheme 72

Scheme 73

Scheme 74

1. Remove the retainers and the air deflector.
2. Remove the power steering reservoir bracket retainers.
3. Remove the power steering fluid indicator and retainers. Remove the power steering reservoir mounting bracket. Install the power steering fluid indicator and position the power steering reservoir aside.
4. Disconnect the coolant hoses from the air cleaner outlet pipe.
5. Loosen the clamps and remove the air cleaner outlet pipe.
6. Loosen the clamps and remove the charge air cooler (CAC) pipe.
7. Remove the secondary fuel filter and remove all fuel from the filter housing.
8. Disconnect the fuel return tube from the regulator cover.
9. Remove the screws and the fuel pressure regulator cover.
10. Remove and discard the fuel pressure regulator cover O-ring seal.
11. Remove the spring and poppet valve. Inspect the fixed orifice for foreign material.
12. Clean the fuel pressure regulator bore in the fuel filter housing.
13. To install, reverse the removal procedure.

SPECIAL TOOL Socket, Fuel Injector Pressure Regulator Valve 303-1112

Scheme 75

Removal and Installation

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
2. Disconnect the wiring harness from the oil filter tube. Loosen the retaining nut and position the oil tube clamp aside.
3. Remove the bolts and position aside the exhaust heat shield.
4. Disconnect the injection pressure regulator (IPR) valve electrical connector.
5. Unsnap and remove the heat insulating wrap.
6. Using the special tool, remove the IPR valve.
7. To install, reverse the removal procedure.

SPECIAL TOOLS Disconnect Tool, Quick Release Coupling 303-755 Fuel Injector Pressure Regulator (IPR) Valve Socket 303-1112 Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent

Scheme 80

MATERIAL SPECIFICATION

Scheme 81

Scheme 82

Scheme 83

Scheme 84

Scheme 85

Scheme 86

Scheme 87

Scheme 88

Scheme 89

1. Remove the turbocharger pedestal. For additional information, refer to «FUEL CHARGING & CONTROLS - TURBOCHARGER»(/ford/cutaway-e350/2004-2007/remont/blowers-superchargers-turbochargers/#fuel-charging-system-turbocharger) .
2. Remove the turbocharger heat shield.
3. Position back the heat insulating wrap and disconnect the fuel injection pressure regulator (IPR) valve electrical connector.
4. Unsnap and remove the heat insulating wrap.
5. Remove the IPR valve.
6. Remove or loosen the bolts as needed.
7. Use a thin gasket scraper to separate the cover from the crankcase at the rear cover seam.
8. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
9. Loosen the bolts on the high-pressure tube assembly.
10. Remove the bolts and the high-pressure oil pump.
11. Remove and discard the lower O-ring seals.
12. Using the special tool, disconnect and remove the high-pressure tube assembly.
13. Remove and discard the high-pressure oil pump O-ring seal.

Scheme 90

Scheme 91

Scheme 92

Scheme 93

Scheme 94

Scheme 95

Scheme 96

1. Install a new O-ring seal on the high-pressure oil pump.
2. Install the high-pressure tube assembly.
3. Install new lower O-ring seals.
4. Install the high-pressure pump and bolts.
5. Tighten the bolts for the high-pressure tube assembly.
6. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
7. Install a new press-in-place gasket in the high-pressure pump cover.
8. Clean the cover mounting surface and apply sealer at the seams.
9. Install the high-pressure oil pump cover and remaining bolts.
10. Install the IPR valve.
11. Install the heat insulating wrap and fasten the snap.
12. Connect the IPR valve electrical connector and position back the heat insulating wrap.
13. Install the turbocharger heat shield and bolts.
14. Install the turbocharger. For additional information, refer to «FUEL CHARGING & CONTROLS - TURBOCHARGER»(/ford/cutaway-e350/2004-2007/remont/blowers-superchargers-turbochargers/#fuel-charging-system-turbocharger) .

Scheme 97

1. Disconnect the negative battery cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Disconnect the ICP sensor electrical connector.
3. Remove the ICP sensor.
4. To install, reverse the removal procedure. Verify the sensor O-ring seal is in place.

SPECIAL TOOLS Impact Slide Hammer 100-001 (T50T-100-A) Injector Sleeve Brush Set 303-DS110 (D94T-9000-D) or equivalent Remover, Fuel Injector Sleeve 303-768 Installer, Fuel Injector Sleeve 303-767

Scheme 98

Scheme 99

MATERIAL SPECIFICATION

Scheme 100

Scheme 101

Scheme 102

1. Remove the cylinder heads from the engine. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the lifting bracket from the cylinder head.
3. Insert the injector sleeve tap and injector sleeve tap pilot into the cylinder head fuel injector bore. Tighten the injector sleeve tap 1-1/2 to 2 turns.
4. Install the fuel injector sleeve removal tool into the threaded sleeve. Using the special tools, remove the fuel injector sleeve from the cylinder head fuel injector bore. Discard the sleeve.
5. Using the special tool, clean the fuel injector bore of deposits and hardened sealant.
6. Remove the fuel rail plug. Clean the fuel gallery with a wire brush. Use filtered compressed air to remove foreign material from the gallery. Install the fuel rail plug.

Scheme 103

Scheme 104

1. Verify the fuel injector bore is clean and dry.
2. Position the fuel injector sleeve onto the Injector Sleeve Installer. Apply Threadlock 262® or equivalent to the very bottom (smallest diameter) and very top (largest diameter) flat areas.
3. Position the fuel injector sleeve into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel injector bore, using a rubber mallet. If any sealant gets into the inside of the injector sleeve, it must be cleaned out before it hardens.
4. Install the lifting bracket on the cylinder head.
5. Install the cylinder heads. For additional information, refer to «ENGINE - 6.0L DIESEL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

See also:
• FUEL TANK & LINES
• INTRODUCTION -- 6.0L DIESEL
• ENGINE - 6.0L DIESEL
• INTERIOR TRIM AND ORNAMENTATION
• FUEL CHARGING & CONTROLS - TURBOCHARGER
• BATTERY, MOUNTING AND CABLES
• FUEL INJECTOR SLEEVE