Ford 6.0L Power Stroke Engine Specs, Problems & Reliability
Ford introduced a newer, more powerful 6.0-liter V8 turbo diesel engine in the second quarter of the 2003 model year. One year later, the 6.0L version completely replaced the time-tested 7.3L Power Stroke, considered one of the best Power Stroke engine. The 6.0L engine was the best way to meet lower NOx (Nitrogen Oxide) emissions standards and even stricter demands in future, thanks to EGR, a variable geometry turbocharger, and more efficient fuel injection system.
The 6.0 Power Stroke has a cast-iron cylinder block with a crankcase bed plate (no main caps) for superb bottom-end strength. Its oil cooler and the high-pressure oil pump are integrated into the engine block. Like the 7.3 diesel, the 6.0 has powdered-metal connecting rods and cast-aluminum pistons. Connecting rods are very strong and durable, known to handle 700rwhp and 1,200-1,300 lb-ft of torque. At the rear of the engine, there is the gear train for the crankshaft, camshaft and high-pressure oil pump.
The engine got cast-iron, high-flow cylinder heads with four valves per cylinder (16 intake valves and 16 exhaust valves; 32 valves total). Cylinder heads are attached to the block using just four TTY head bolts per cylinder. Bolts are 14 mm in diameter. The diameter of the intake valves is 33.8 mm (1.33 in), of exhaust valves - 28.0 mm (1.10 in). The cylinder head has two separate intake runners per cylinder. The valves were placed in a "twisted" position helping introduce swirl into the combustion chamber. Each head has an aluminum rocker box mounted to the top.
The 6.0 Power stroke engine features an HEUI (Hydraulically Actuated Electronically Controlled Unit Injection). The fuel injection timing and fuel pressure are controlled by high-pressure oil and electronics. The HEUI system consists of the PCM (Powertrain Control Module), IDM (Injector Driver Module), the swash-plate style high-pressure oil pump (HPOP), IPR (Injection Pressure Regulator), and Siemens injectors. The HPOP is located under the HPOP cover and turbocharger at the rear of the engine. The Split-shot HEUI fuel injection system allows the 6.0 PowerStroke to produce higher injection pressures throughout the entire operating range (in-cylinder fuel injection pressure can reach 26,000 psi).
The 6.0L engine was the first in Power Stroke family equipped with single variable geometry turbocharger (VGT). It utilizes the Garrett GT3782VA turbocharger with electronically controlled and hydraulically actuated vanes and 58mm compressor wheel. A charged air goes through an air-to-air intercooler. This quick-spooling turbocharger provides quick throttle response.
The 6.0L Power Stroke proved to be less reliable than its 7.3L predecessor and was replaced in 2008 by a more powerful, durable, and emissions friendly 6.4L Power Stroke.
Engine Specs
6.0 Power Stroke Engine Problems and Reliability
The 6.0L Power Stroke has a poor reputation in terms of reliability and durability. In the first place in the list of problems are EGR-related issues: cracked EGR coolers and failed EGR valves. The exhaust gas recirculation (EGR) system is sources of the main issues with the 6.0L Power Stroke. Aluminum tubes that go to the oil cooler have the tendency to crack from temperature changes. These cracks usually result in oil pushing its way into the cooling system and forming high-viscosity coolant due to the mixture with oil. That leads to cracking of the EGR cooler's coolant passages and leaking coolant into the intake system. This usually appears as white smoke from the exhaust pipe. Also, the EGR valve is often coated with soot and stuck in the open/closed position. A gummed up EGR valve is usually caused by long engine runs at idle or low speeds.
The coolant in the intake increases cylinder pressure due to a steam build-up, leading to stretching of the Torque to Yield (TTY) head bolts. That is the reason for the second common problem with the 6.0L - head gasket failures. 4 torque to yield head bolts per cylinder is simply not enough to prevent the engine from blown head gaskets. There are some aftermarket solutions for replacing the factory bolts with head studs, but studs increase the risk of cracks or deformation of the cylinder head.
There are a few more well-known problems on the list: injection system issues related to bad injectors, air leaks, O-rings on stand pipes, ICP and IPR sensor failures, and FICM failures; HPOP's problems; VGT turbocharger is prone to sticking open or closed; cylinder heads are known to crack.
7.3L's reliability is not what should be expected from the 6.0 Power Stroke engine, but horsepower, drivability, and meeting modern-day emissions standards.