Technical Service Bulletins
|Publication Date: October 7, 2003|
|1998-2000 E SERIES|
1999-2000 SUPER DUTY F SERIES
This article is being published to combine TSB 00-22-1 and 01-14-6 as part of a consolidated 7.3L diagnostic aid booklet.
Some vehicles equipped with a 7.3L Powerstroke diesel engine with engine serial number 661894 through 1311240, may exhibit a noise above the normal sound of the diesel combustion. This noise may sound like a rod knock, but it is intermittent and increases in intensity as the engine warms up to operating temperature. This “cackle” noise may by caused by pressure variation within the fuel rail and in virtually all instances is attributed to cylinder #8 (driver side rear). The “cackle” noise does not cause damage the engine, or impact the engine’s performance or economy.
Engines after serial number 1311240 were built with a long lead injector in cylinder #8 and correct calibration from the factory. It is possible for engines with the long lead injector, from the factory or installed in service, to exhibit a “lifter noise” (the long lead injector can be identified by the “LL” stamp on top of the solenoid.) This noise is typically most noticeable when the vehicle is parked next to a brick or concrete wall, such as at a fast food drive through. This noise is a normal characteristic of the long lead injector and is not a reason to replace the injector.
Refer to the following Service Procedure for diagnostics, injector replacement, and Powertrain Control Module (PCM) reprogramming procedure.
The “cackle” noise will typically be found early in an engine’s life due to low fuel pressure and/or the relationship of injectors and engine firing order, or fuel pressure below specification. If a mature engine develops the “cackle” noise, low fuel pressure is the likely cause. Before making a repair attempt, the following tests should be performed:
- Verify that the noise occurs with a hot engine, not cold.
- Verify that the vehicle has been driven long enough to purge the air out of the high-pressure oil system and the fuel system since the last injector/high pressure oil system repair. Air trapped in the system could induce the “cackle” noise.
- If the fuel pressure is less than 379 kPa (55 psi) in either head, repair it first and re-evaluate the “cackle” concern.
- Repair any other engine driveability concerns prior to attempting a repair for “cackle”. Example: low fuel pressure concerns may be causing low power and “cackle”. Repairing the low fuel pressure may correct both concerns. Also, an engine miss may be an indicator of valve train concerns.
- Verify that there is no air entering the fuel system. Air entering the fuel system will affect injector timing, causing unusual noise/performance.
- The Injector Performance Analyzer can be used to determine if the “cackle” is coming from cylinder #8. Cancel that cylinder to determine whether the noise still exists. “Cackle” cannot be identified using the Cylinder Contribution Test.
If the noise is only present when engine is hot, and:
- no performance concern exists
- fuel pressure is above the minimum specification of 379 kPa (55 psi)
- there is no air present in the fuel/oil system
- a long lead injector is currently not installed
then the engine is a candidate for a special Injector, F81Z-9E527-EARM (engine s/n 661894 – 896811) or XC3Z-9E527-AARM (engine s/n 896812 – end of 7.3L production).
NOTE: IF THE NUMBER EIGHT INJECTOR HAS BEEN REPLACED PREVIOUSLY FOR A CACKLE NOISE CONCERN WITH PART NUMBER NOTED ABOVE, DO NOT REPLACE IT AGAIN. THE LONG LEAD INJECTOR CAN EXHIBIT A TICKING “LIFTER” NOISE AT NORMAL OPERATING TEMPERATURES. THIS IS CONSIDERED A NORMAL CONDITION AND DOES NOT REQUIRE SERVICE. NOTE: THE ENGINE SERIAL NUMBER CAN BE FOUND ON THE LOWER LEFT SIDE OF THE ENGINE BLOCK REARWARD OF THE OIL FILTER. NOTE: THE NEW LONG-LEAD INJECTOR FOR “CACKLE” NOISE IS USED ONLY IN CYLINDER #8. DO NOT USE IN ANY OTHER CYLINDER DUE TO FUTURE CYLINDER CONTRIBUTION TEST DIAGNOSTICS BEING AT RISK. THE INJECTOR IS RECOGNIZABLE BY AN “LL” STAMPED ON THE SOLENOID WHERE THE UVC (INJECTOR HARNESS) CONNECTS.
Replace the #8 injector by referring to the replacement procedure in the appropriate vehicle Workshop Manual. In addition to replacing the injector, the PCM MUST be reprogrammed to prevent the #8 injector from flagging a false Cylinder Contribution Test code during future diagnostic tests. After the repair, realize that some small amount of “cackle” may remain.
NOTE: VEHICLES BUILT WITH ENGINE AFTER S/N 1311240 HAVE CORRECT CALIBRATIONS FROM THE FACTORY. PCM CALIBRATION INFORMATION Application Old Part Number (-12A650-) Old Tear Tag New Part Number (-12A650-) New Tear Tag NGS/WDS Qualifier F-250/350 M/T Federal Service Fix 1999.5 XU2F-UA QEK0 XU2Z-UB QEK1 WDS Release B26.4 or Later F-250/350, F-450/550 M/T Federal Service 1999.5 XU2F-PA ZHL0 XU2Z-PB ZHL1 WDS Release B25.4 or Later F-450/550/560 M/T 50S Service Fix 1999.5 XU2F-XA VRP0 XU2Z-XB VRP1 WDS Release B25.4 or Later F-450/550/560 M/T 50S Service Fix 1999.5 XU2F-VA BAW0 XU2F-VB BAW1 WDS Release B25.4 or Later F-250/350 M/T California Service Fix 1999.5 XU2F-YA GLI0 XU2Z-YB GLI1 WDS Release B25.4 or Later F-250/350 M/T California Service Fix 1999.5 XU2F-SA SBJ0 XU2Z-SB SBJ1 WDS Release B25.4 or Later F-250/350 A/T Federal Service Fix 1999.5 XU2F-ZA YEV0, YEV1, YEV2 XU2Z-ZD YEV3 WDS Release B25.4 or Later F-250/350, F-450/550 A/T Federal Service 1999.5 XU2F-RA MRT0, MRT1, MRT2 XU2Z-RD MRT3 WDS Release B25.4 or Later F-450/550/560 A/T 50S Service Fix 1999.5 XU2F-ABA RXM0, RXM1, RXM2 XU2Z-ABD RXM3 WDS Release B25.4 or Later F-450/550/560 A/T 50S Service Fix 1999.5 XU2F-AAA LVS0, LVS1, LVS2 XU2Z-AAD LVS3 WDS Release B25.4 or Later F-250/350 A/T California Service Fix 1999.5 XU2F-ACA XWF0, XWF1, XWF2 XU2Z-ACD XWF3 WDS Release B25.4 or Later F-250/350 A/T California Service Fix 1999.5 XU2F-TA HQN0, HQN1, HQN2 XU2Z-TD HQN3 WDS Release B25.4 or Later E-350/450 A/T Federal Service Fix 1999.5 XU2F-ADA UYQ0 XU2Z-ADB UYQ1 WDS Release B25.4 or Later E-350/450 A/T California Service Fix 1999.5 XU2F-AEA JUK0 XU2Z-AEB JUK1 WDS Release B25.4 or Later E-350/450 A/T California Service Fix 2000 XC2F-AND CHK3, CHK4 XC2Z-ANF CHK5 WDS Release B25.4 or Later E-350 A/T California Service Fix 2000 XC2F-BBA MYA0 XC2Z-BBB MYA1 WDS Release B25.4 or Later F-250/350 M/T California Service Fix 2000 XC3F-CF ATA3 XC3Z-CG ATA4 WDS Release B25.4 or Later F-250/350 M/T California Service Fix 2000 XC3F-DF FHP3 XU7Z-DA FHP4 WDS Release B25.4 or Later Excursion A/T 50S Service Fix 2000 YC3F-ARF ZYS5 YU7Z-BA ZYS6 WDS Release B25.4 or Later Excursion A/T 50S R/C 2000 YC3F-AVA AXD0 YU7Z-AA AXD1 WDS Release B25.4 or Later F-250/350 M/T Federal R/C 2000 XC3F-AF DAC3 XC3Z-AG XPC4 WDS Release B25.4 or Later F-450/550 M/T California R/C 2000 XC3F-KF VXY3 XC3Z-KG VXY4 WDS Release B25.4 or Later PCM CALIBRATION INFORMATION Application Old Part Number (-12A650-) Old Tear Tag New Part Number (-12A650-) New Tear Tag NGS/WDS Qualifier F-250/350 A/T California R/C 2000 XC3F-EBD NVK3, NVK4 XU7Z-AB NVK5 WDS Release B25.4 or Later F-250/350 A/T California R/C 2000 XC3F-PF CNH4 XU7Z-BA CNH5 WDS Release B25.4 or Later F-250/350 M/T California R/C 2000 XC3F-DCA HMR0 XC3Z-DCB HMR1 WDS Release B25.4 or Later F-450/550 A/T CFFV R/C 2000 YC3F-BCA YLE0 YU7Z-CA YLE1 WDS Release B25.4 or Later F-250/350 A/T California R/C 2000 XC3F-DDA UKN0 XU7F-CA UKN1 WDS Release B25.4 or Later E-350/450 A/T Federal R/C 2000 XC2F-APD SZT3, SZT4 XC2Z-APF SZT5 WDS Release B25.4 or Later E-350/450 A/T Federal R/C 2000 XC2F-BAA RCU0 XC2Z-BAB RCU1 WDS Release B25.4 or Later E-350/450 A/T California R/C 2000 XC2F-AZB FHM1 XC2Z-AZC FHM2 WDS Release B25.4 or Later E-350 A/T California R/C 2000 YC2F-ATB SBR1 YC2Z-ATC SBR2 WDS Release B25.4 or Later F-250/350 M/T Federal Warm Weather 1999 F81F-JE BDT4 F81Z-JF BDT5 WDS Release B27.8 or Later F-250/350 M/T Federal Cold Weather 1999 F81F-AF AWA4 F81Z-AG AWA5 WDS Release B27.8 or Later F-450/550/560 M/T 50S Warm Weather 1999 F81F-LE DYK4 F81Z-LF DYK5 WDS Release B27.8 or Later F-450/550/560 M/T 50S Cold Weather 1999 F81F-KE CLB4 F81Z-KF CLB5 WDS Release B27.8 or Later F-250/350 M/T California Warm Weath 1999 F81F-ME ETR4 F81Z-MF ETR5 WDS Release B27.8 or Later F-250/350 M/T California Cold Weath 1999 F81F-CF ZDR4 F81Z-CG ZDR5 WDS Release B27.8 or Later F-250/350 A/T Federal Warm Weather 1999 F81F-NG FUT6, FUT7 F81Z-NJ FUT8 WDS Release B27.8 or Later F-250/350 A/T Federal Cold Weather 1999 F81F-BH XLE6, XLE7 F81Z-BK XLE8 WDS Release B27.8 or Later F-450/550/560 A/T 50S Warm Weather 1999 F81F-RG HPA6, HPA7 F81Z-RJ HPA8 WDS Release B27.8 or Later E350/E450 A/T Federal 1998-1999 F8UF-AFG MLU6 F8UZ-AFH MLU7 WDS Release B27.8 or Later E350/E450 A/T California 1998-1999 F8UF-AGG PTH6 F8UZ-AGH PTH7 WDS Release B27.8 or Later
Obtain an Authorized Modifications Decal (FPS 8262 – obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.
AUTHORIZED MODIFICATIONS THE FOLLOWING MODIFICATIONS HAVE BEEN MADE: Replaced or Reprogrammed Powertrain Control Module (PCM) per TSB 03-21-39. THESE MODIFICATIONS HAVE BEEN APPROVED, AS APPROPRIATE, BY EPA AND CARB. DEALER NUMBER:——————————————DATE:
FPS 8262 9/78 FORD MOTOR COMPANY PRINTED IN U.S.A.
|PART NUMBER||PART NAME|
|F81Z-9E527-EARM||#8 injector (s/n 661894 – 896811)|
|XC3Z-9E527-AARM||#8 Injector (s/n 896812 – end of 7.3L production)|
OTHER APPLICABLE ARTICLES:
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