Fulltext TSBs

Technical Service Bulletins

TSB
03-21-33
  • ENGINE – 7.3L DIESEL – 1999 ENGINE CONTENT REVISIONS
Publication Date: October 7, 2003

FORD:
1999 E SERIES, SUPER DUTY F SERIES

Article 99-7-7 is being republished in its entirely as part of a consolidated 7.3L diagnostic aid booklet.

ISSUE:

Significant changes have been made to the 7.3L DIT engine effective with the release of the 1999.5 Model Year (MY) (December 1998). The major areas addressed are the air intake system, turbocharger, injectors, and air cleaner.

ACTION:

Refer to the following text and Part Application Chart for the correct part description and correct part usage when servicing subject engines.

SERVICE PROCEDURE

HIGHLIGHTS

Fuel System

  • Tungsten carbide-coated injector plunger and barrel. Lessens the chance of injector damage by low lubricity fuel and water.
  • New fuel pressure regulator (1999 MY). Fuel pressure on all Powerstroke engines built since 1/18/1998 or engine Serial Number (S/N) 551496 should be 352 31 kPa (51 4.5 psi) at idle.
  • NOTE:THE NEW INJECTORS AND/OR PUMP CANNOT BE USED IN PRE-1999.5 MODEL YEAR ENGINES AND THE PRE-1999.5 MODEL YEAR PUMP AND INJECTOR CANNOT BE UTILIZED IN 1999.5 MODEL YEAR ENGINES.

  • A dual element fuel filter was incorporated during the 1999 model year to filter the fuel that is returned to the tank via the fuel filter regulator. The Ford Replacement Part number for this filter is now F81Z-9N184-AA (Figure 1).

High Pressure Oil System

  • New high pressure oil gallery plug for service that places the sealing O-rings deeper into the gallery. The new plug is identified with a circular groove cut into the face of the plug. The new plug went into production prior to the 1999.5 MY on engine S/N 751869 (Figure 2).
  • New high pressure oil pump with higher flow rate (7.2cc versus 6.8cc 1999 model year and prior).

Turbocharger

  • New higher efficiency turbocharger. Turbo compressor outlet diameter and compressor size increased to improve air flow. Taller pedestal provides better clearance (Figure 3).
  • New exhaust inlet adapter allows access to the fuel pressure test port at the rear of the head.
  • New exhaust up-pipes with inlet adapter.
  • Econoline uses the new larger, taller turbo without the wastegate or charge air cooling provisions.

Charge Air Cooler

  • New Charge Air Cooler (CAC) crossover is incorporated with the new turbo (Figure 4).
  • A Powertrain Control Module (PCM)-controlled intake air heater is installed in the air inlet (after the CAC) to the engine side of the CAC crossover. The Econoline heater is in the Y-pipe downstream of the turbo. The new intake heater is used to heat the air before it reaches the combustion chamber in the engine during cold startup to reduce cold smoke. Current to the intake heater is switched on/off by a PCM-controlled relay, similar to the glowplug relay (Figure 5).
  • Both E- and F-Series use a new intake cover with 76mm (3″) inlets into the heads for better flow to the combustion chambers (Figure 6).

PART APPLICATION
Part Name1999.5 Part NumberPrevious Part Number
Air Heater RelayF81Z-6G015-AA
Air HeaterF81Z-9N424-AA
Air Heater Insulator1831643-C1 (N*)
Air Heater Sealing Washer1827886-C1 (N*)
Air Heater Wave Washer1831644-C1 (N*)
Air Cleaner (F-Series)XC3Z-9600-AAF81A-9600-AD
Charge Air Cooler (CAC) Duct-to-Intake ManifoldF81Z-6K889-CAF81A-6K889-AA
Cylinder Head Covers (Econoline/F-Series)F81Z-9E434-CA
Engine Wiring Harness – Federal (F-Series)F81Z-12B637-EA
Engine Wiring Harness – California (F-Series)F81Z-12B637-DA
Engine Wiring Harness – Federal (Econoline)XC2Z-12B637-EA
Engine Wiring Harness – California (Econoline)XC2Z-12B637-FA
Exhaust Muffler Extension Pipe (156.2″ W.B.)XC3Z-5A212-BA
Wide Frame – Exhaust Muffler Extension Pipe (F-Series 172.4″ W.B.)XC3Z-5A212-CA
Wide Frame – Exhaust Muffler Extension Pipe (F-Series 158″ W.B.)XC3Z-5A212-DA
Wide Frame – Exhaust Muffler Extension Pipe (F-Series 141.8″ W.B.)XC3Z-5A212-EA
Wide Frame – Exhaust Muffler Extension Pipe (F-Series 164.8″ W.B.)XC3Z-5A212-FA
Narrow Frame – Exhaust Muffler Extension Pipe (F-Series 176.2″ W.B.)XC3Z-5A212-GA
Narrow Frame – Exhaust Muffler Extension Pipe (F-Series 161.8″ W.B.)XC3Z-5A212-HA
Narrow Frame – Exhaust Muffler Extension Pipe (F-Series 200.8″ W.B.)XC3Z-5A212-JA
Narrow Frame – Fuel Filter Element PackageF81Z-9N184-AAF81Z-9N184-AA
Fuel Supply And Return LinesF81Z-9J338-NAF81A-9J338-NA
High Pressure Oil PumpF81Z-9A543-CRMF81A-9A543-BA
Injector (Tungsten Carbide)F81Z-9E527-BRMF81A-9E527-ARM
Power Feed Cable (Econoline)XC2Z-12B568-BA
Regulating Valve PackageF81Z-9B249-BBF81Z-9B249-BA
Turbocharger Exhaust Inlet AdapterF8TZ-6K854-AA
Turbo Pedestal With Exhaust Back Pressure (EBP)F81Z-6N639-CARMF81A-6N639-AA
Turbo Pedestal Without EBP (F-Series)F81Z-6N639-DARMF81A-6N639-BA
Turbocharger With EBP (F-Series)F81Z-6K682-BARMF81A-6K682-AA
Turbocharger Without EBP (F-Series)F81Z-6K682-CARMF81A-6K682-AARM
Turbocharger Without EBP (Econoline)XC2Z-6K682-AARMF8UZ-6K682-AARM
Wastegate Actuator Kit With EBP (F-Series)F81Z-6F089-AA
Water Drain Cable (Econoline)XC2Z-9J312-AAF7UA-9J312-AA

(N*) Navistar

OTHER APPLICABLE ARTICLES:

NONE

SUPERSEDES:

99-7-7

WARRANTY STATUS:

Information Only




Figure 1 – Article 03-21-33




Figure 2 – Article 03-21-33




Figure 3 – Article 03-21-33




Figure 4 – Article 03-21-33




Figure 5 – Article 03-21-33




Figure 6 – Article 03-21-33


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

Copyright 2003 Ford Motor Company