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Hello fellow FTE'ers. I'm usually in the 7.3 forum but am in need of your assistance. A good friend of mine just bought a 2003 xlt with the 6.0 and has an oil leak at the HPOP cover as far as he can tell. Do you know of a good write up that explains how to get to where we need to go. Also maybe a list of o-rings and gaskets that will be needed on the journey. Is there anything else that may need attention while we are in that deep. I have read about the SVT fitting but not sure what that is or where. The EGR has been deleted. Thanks for your help
How many miles? The HPOP is the weak link on the 03. You also might proactively look at the ICP sensor to see if is oil soaked. If so it would be a good idea to replace the sensor and pigtail.
That's all I got, because I haven't had an opportunity to work on an 03/04.
Yes I'm looking for the gasket replacement procedure or even a picture or two would help. The engine I believe has been rebuilt just unsure of how many miles since it was done. The truck itself has 175000. I know we will need the orings for the cover just unsure of what the turbo will need and anything else that is attached to it. We would like to have everything needed before we start so we won't have to chase parts. This will be the first time working on a 6.0 and very interested to learn I've read about the horror stories but always up for a challenge.
Send me a PM to remind me and I'll get you the relevant pages from the Ford
03~04 Shop Manual in PFD format. One word of cation and the PDF will also
same something about it. When you pull the cover you need to remove the RTV
at both rear corners. If you find no RTV that may be the reason for the leak.
Little dab in the rear corners where the 3 surfaces join.
Once I wake up and the PC has come back to life I'll get the files.
Ok I have you an overload of into here. You only need parts of it so your will
want to read it and pick out what is relevant to you job.
The instructions show removing the engine but that is not needed.
The intake gaskets are reusable if they are undamaged. The oil cooler
and filter can be left in place. The only reason to remove them would be
if you find the IPR screen is trashed. Then you might want to pull the
cooler and clean the reservoir and check/replace it's screen if damaged.
ONE THING if you so clean it suction hun the oil out and don't use any
towels. You don't want any lint or string fragments in there at all.
I have seen and heard that brake cleaner spray does a good job in cleaning.
Just be sure to suction it all out and it the HPOP is out may as well clean the
connection between the two points and suction dry.
One thing I would add to the removal of the cover is have a sharp blade
to go under the cover back edge after you have all the bolts out. This way
you don't pull the ends of the rear cover seal out of place. Not sure if the
03~04 has them or not. But better safe then sorry. Just cut the RTV. Also
while you have the IPR out check the screen for any trash or damage. Replace
it if needed. It will be a lot less of a pain while you have direct access.
Sorry for all the extra info but may need some but I hope it not the case.
I think it's worth noting, and think the experts here would agree, use the FORD silicone on this repair for the two dabs at the back corners where the HPOP cover meets the back plate. It's going to seem like overkill for that tube, just for the two smaller dabs but I spent some time researching this and it's the one thing that most of the posts I read stressed, was to use the real Motorcraft stuff. It comes in a tube about half the size of a regular caulk tube, and goes in a normal caulk gun. This is one area you don't want to take apart again after using something else to save a few bucks.
Part# is shown on the first page of the second PDF that Sean posted. It's good stuff and the only thing most guys will use.
Be careful as well scraping the old silicon off, you don't want to dig too hard, or might damage the gasket for the back cover that is right there at that joint as well. Be sure to check the expiration date on the tube, it does have a shelf life.
I would first be closely examining the icp sensor. I rarely see the cover cause leaks,, but EVERY 03 I go into either is leaking, was, or is gonna leak from the sensor. VERY high leak point is just the sensor.
I would first be closely examining the icp sensor. I rarely see the cover cause leaks,, but EVERY 03 I go into either is leaking, was, or is gonna leak from the sensor. VERY high leak point is just the sensor.
Great point there, when I initially thought I had a bad ICP, which I did(along with the HPOP) I had a pretty good drip coming off the sensor area which could have easily been mistaken for a leaky HPOP cover. Mine was so bad it worked it's way up the wiring loom even almost to the point where the IPR branches off that same loom. Pigtail and plug were just soaked. It still worked but was on it's way out obviously.
Here is a good vid from Ron about the ICP on an '03. I found getting at it from under was really not that bad, but I have long arms and not huge forearms lol, which helps. IIRC there are two 10mm bolts and one 13mm bolt for the heat shield that is a little tricky to get at but with the right combo of ext and IIRC a short swivel can be done. I had to do some by feel but it's easier than the topside where the FICM has to come out.
At any rate, you will need a socket to get that sensor off. I went and bought one and just cut it down a little bit. Because of clearance issues you can't just buy a full deepwell and get your ratchet on the end.
Just wanted to update this thread. We repaired the oil leak but it wasn't the hpop cover it ended up being the what i'm guessing is the oil cooler cover on the top towards the front. So thank you all for your help. Now on to the next challenge. The truck will start briefly then quit and repeat this process until the batteries drain. I'm letting him use my scangauge II so he can monitor and check for codes. He hasn't read for codes yet if any but will post what we find. What PID's do we need to watch while cranking I know we need the ICP IPR% RPM or maybe a list of said items. I checked the tech folder but didn't see anything labeled PID list.
