Engine 6.0L Diesel: Diagnosis Ford Econoline E150

Powertrain Control/Emissions Diagnosis

For diagnosis and testing of the electronic engine control system, refer to the INTRODUCTION - DIESEL article.

Scheme 1400

1. Verify the customer concern.
2. Visually inspect for obvious signs of damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the concern is not visually evident, check the base oil pressure.
5. Install the tool and check the base oil pressure. The minimum engine oil pressure specifications are 82.7 kPa (12 psi) at 700 rpm, 165.5 kPa (24 psi) at 1,200 rpm and 310.3 kPa (45 psi) at 1,800 rpm with the engine at operating temperature.
6. If the concern is not evident, verify the symptom. GO to «SYMPTOM CHART»(ref-213720-S28788790382005123000000) .

Scheme 1401

Scheme 1402

Scheme 1403

Scheme 1404

1. Clean the pistons with liquid soap and water.
2. Break the old compression rings in half, then use the compression rings to clean the piston ring groove areas of the piston.
3. Inspect the piston ring lands, skirts, oil ring slot corners and pin bosses for scoring, scuffing or cracks. Install a new piston if these types of damage appear.
4. Measure keystone piston ring groove wear. Select 2.08 mm (0.082 in) piston gauge pins. Install the gauge pins in the top groove. Using a micrometer, measure the distance between the gauge pins. Install a new piston if not within specification.
5. Measure the piston pin diameter in two directions at the points shown. Verify the diameter is within specification. If out of specification, install a new piston pin.
6. Measure the outside diameter of the piston pin and the inside diameter of the piston pin bore. The difference between the two readings is the piston pin-to-bore clearance. Install a new piston pin or piston if not within specification.

Scheme 1405

Scheme 1406

Scheme 1407

1. Using a suitable solvent, thoroughly clean the connecting rod and rod cap.
2. Mark each connecting rod and its corresponding rod cap for correct installation.
3. Measure the inside diameter of the piston pin bushing. Install a new connecting rod, if not within specification.
4. Using a suitable micrometer, measure the connecting rod bearing bore. Remove the connecting rod bearings from the connecting rod and the connecting rod cap. Install the connecting rod cap onto the connecting rod and tighten the bolts. Further tighten the connecting rod cap bolts. Measure and record the connecting rod bearing bore as indicated. Install new connecting rods if not within specification.
5. Using a suitable micrometer, inspect the connecting rod bearing bore taper. Measure the bearing bore inside diameter near the large chamfer. Measure the bearing bore inside diameter near the small chamfer. The difference between the two readings is the bore taper. Install new connecting rods if not within specifications.

Oil Pump Rotor Inspection

SPECIAL TOOL(S)

Scheme 1408

Scheme 1409

Scheme 1410

1. Inspect the oil pump for excessive metal particles.
2. Inspect the oil pump for gouging, cracks or deep scratches.
3. Inspect the oil pump inner and outer gear rotors for damage or excessive wear.
4. Using a straightedge and the Feeler Gauge, measure the height clearance between the oil pump housing and the inner and outer rotors. If the measurement does not meet specifications, install new gerotors as a set.
5. Using the Feeler Gauge, measure the clearance between the outer rotor and the oil pump housing. If the measurement does not meet specifications, install new gerotors as a set.

Rocker Arm Cleaning and Inspection

MATERIAL

MATERIAL CHART

Scheme 1411

Scheme 1412

Scheme 1413

Scheme 1414

Scheme 1415

1. Disassemble the rocker arm from the fulcrum plate. With the rocker arm and fulcrum plate upside down in your palm, push down in your palm, push up on the rocker arm and with your palm push down on the fulcrum plate.
2. Move the rocker off the ball, keeping the ball in the detent of the fulcrum plate. Remove the rocker arm ball.
3. Remove and discard the rocker arm clip.
4. Clean all parts with a suitable solvent. Use filtered compressed air to dry the parts. Inspect each rocker arm pivot foot and corresponding valve bridge for pitting and scuffing. Inspect each rocker arm ball and socket for scuffing. Install new rocker arms and valve bridges as required. Inspect the rocker arm post ball socket for excessive wear. Inspect bolts for thread damage, install new components if worn or damaged.
5. Install a new rocker arm clip on the fulcrum plate.
6. Insert the ball in the detent in the fulcrum plate and lubricate with clean engine oil. Hold the rocker arm upside down in your palm.
7. Press the lower part of the rocker arm against the rocker arm clip, push up with your palm and push the upper part of the rocker arm over the rocker arm ball. Check for freedom of movement of the rocker arm on the fulcrum plate.

Inspection

1. Inspect the cylinder block for cracks not visible to the eye. Coat the suspected area with a mixture of 25 percent kerosene and 75 percent light engine oil. Wipe the area dry, and immediately apply a coating of zinc oxide dissolved in wood alcohol. If cracks are present, the coating will become discolored at the damaged area.

1. With valves installed to protect the valve seats, remove deposits and gasket material from the valve heads and gasket surface with a scraper and wire brush. Be careful not to damage cylinder head gasket surface.
2. Use a suitable solvent to remove dirt, grease and other deposits from the removed parts.
3. Clean all bolt holes and be sure gasket surfaces, oil return holes, and coolant passages are clean. After rinsing thoroughly with hot water, blow them out using filtered compressed air.
4. Wash all bolts (except head bolts, these must be replaced) with a suitable solvent and dry thoroughly.
5. Inspect the cylinder head for cracks, burned valves or seats and scratched or marred gasket mating surfaces.
6. Measure the cylinder head thickness. If the deck-to-deck measurements are not within specifications, install a new cylinder head.