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I purchased an 04 CCLB last week. According to the seller the engine was replaced in 08 with a “gen 2” under warranty by a ford dealer. I have a copy of the work order from the dealer that shows the replacement.
The truck has only had 39k put on since the engine replacement (tires were even date coded for 08) and is 100% stock with the exception of an added coolant filter.
I read through the thread on differences over the years and it would be helpful for future upgrades to know where I stand. 2003-2004.25 or 2005-2007 or some *******ized mix.
Any recommendations on what to look for to make a half educated guess would be appreciated.
Before beginning, it is important to note that the engine AND truck production dates (hence the date a new model year is introduced) do not match the calendar years. Typically the production year begins in June of the year PRIOR TO the new model years truck/engine. Hence (as an example), an '05 truck had its production run started sometime in June of '04. Same thing happens for ALL model years.
PLEASE NOTE that much of this post will be somewhat repetitious to what I put in the original "model year differences" thread (link provided in the OP's opening post of this thread), but in this post I am focusing mainly on the "visible differences" and also posting links to pictures that highlight these changes. This is to help people be able to fairly quickly identify what they have. IMO the attached pics in this thread are what provide the most benefit.
To answer your question:
Start by finding your ICP sensor. It will be behind the turbo (near the IPR valve) or on the passenger side valve cover.
Then tell us if your GPCM (Glow Plug Control Module) is oriented horizontally or vertically.
Then tell us if your HPOP cover is cast iron or aluminum.
Then measure the diameter of the core plugs in the head.
OR ............
Take pictures of them and post here, and we will tell you what you have.
Pictures of these components can be found in the Coffee Table Books for each year AND, I have included links to pictures of these differences:
2003 key pics:
Note the round aluminum HPOP, cast-iron HPOP cover, and ICP sensor location by the IPR valve at the HPOP cover
For reference, see the links at the bottom of this post to the 2003 Ford/International Coffee Table Books (6.0L bible)
2004.5 (on 9-29-03) key pics:
Note the ICP sensor on the passenger valve cover and the horizontal GPCM orientation.
Note ALSO that the early 2004 model year still had an '03 engine. It wasn't until 9-29-03 that the '04 engine was installed in the '04 truck. This 04 engine had the same style HPOP as the 03 engine, but had wavy oil rails so the ICP sensor was relocated. Also, the Glow Plug wiring went from a sold "buss bar" design to harnesses. Not also that the glow plugs were shortened for the '04 engine and these shorter glow plugs MUST BE USED or engine damage might occur:
For reference, see the links at the bottom of this post to the 2004 Ford/International Coffee Table Books (6.0L bible)
2004 running changes (sometime after 9-29-03) key pics:
Note - the fuel supply line trap was added.
For reference, see the links at the bottom of this post to the 2005 Ford/International Coffee Table Books (6.0L bible) for 2004 running changes.
Late-Late '04's key pic:
Note - went to a vertical GPCM orientation - I think in January of '04 - (and involved a wiring harness change).
For reference, see the links at the bottom of this post to the 2005 Ford/International Coffee Table Books (6.0L bible)
In 2005 the front cover was changed to have a different nozzle orientation for the coolant return from the radiator and coolant return fro the heater core. Also, from 2004 to 2005, the EGR throttle plate was deleted.
2005 Running changes key pics:
Note - MAF sensor removed in mid '05, but added back in "late-late" 2005, EBP sensor changed and bracket location changed, and four outer rocker arm carrier (RAC) hold down bolts removed.
For reference, see the links at the bottom of this post to the 2005 "running changes" Ford/International Coffee Table Books (6.0L bible)
Then the next significant changes were made beginning Jan 12, 2006 where the engine was "COMMONIZED"
NOW - all that said above, please note that the commonized engines are often times called 2006 Job 2 engines, so you need to look at these changes to see if you have them. Probably the "most visible change" for the commonized engine was in the core plugs that are in the heads:
New cylinder heads also use 32 mm core plugs replacing the old 28 mm core plugs. The cylinder head gasket is also new to accommodate the new 20mm cylinder head location dowels. Pre commonization head use 18mm dowels.
.
Lastly, below is a link from mchan68 (Mike) that describes the commonized changes (see post #11 in the link below), and confirms that the square cast iron pump (and the STC fitting) was NOT introduced for the 2004.5 model year, but for the 2005 model year. https://www.powerstroke.org/threads/...stion.1372861/
Seriously though - I structured this response to focus ONLY on the most visible differences and then added links to pics (which were not in the original thread). I know it has much of what the original thread did, but the extra pics should have been what you needed, right??
Afterall, the only clues we were given above, were your replacement engine installation year and the "gen 2" designation.
Edit
If all the above is overwhelming, then maybe just start with measuring the diameter of the head's core plugs. That shouldn't be too onerous of a way to start.
Purely timing . I was reading through your original thread and was adding more info to mine. When my reply posted yours posted above it with the links and I thought I replied to the wrong thread (your original). Didn’t realize until this morning what I did.
I really appreciate your advice and will head out to the truck and see what I can learn when we get a little more daylight.
Purely timing . I was reading through your original thread and was adding more info to mine. When my reply posted yours posted above it with the links and I thought I replied to the wrong thread (your original). Didn’t realize until this morning what I did.
I really appreciate your advice and will head out to the truck and see what I can learn when we get a little more daylight.
Bob
Thanks. TBH, I struggle with the amount of detail and verbiage to post since there were just SO MANY changes. There truly is "no short answer". As old as these engines are now, a person literally could have just about ANY of the "flavors" under the hood.
For a bit there, I was thinking that maybe posting the links to the Coffee Table Books again in this thread (similar to the original thread) might be frustrating you. I was trying hard not to just regurgitate what was in that original thread! Perhaps to make this thread a bit more usable to any future readers, I may just pull those links out of the middle and have a table for them at the end.
This dealer opted for a long block, not a complete engine assembly, and transferred everything over. This may be a different source then what I got for an engine replacement, and you got a better one. Your block does not have the thick black paint over it.
It's possible that Ford had two sources, one for short and long blocks, and one for complete engine assemblies. My dealer pushed for the complete assembly to reduce labor costs despite I preferred a long block. They offered a lower price.
