6.0 upgrades

My 03 ride now has 96,000 miles and giving me some issues and curious what you think?

Think my Edge Juice Attitude is about done for - sometimes it works and sometimes the screen doesn't light up and it shuts off and reboots and while the engine stops for a few seconds, then back to normal. I honestly don't know if it is the Edge product or FICM or both. The FICM volts vary from 47 to 48.5 when I am looking at it and monitoring it with Torque Pro App via Bluetooth OBD2 gizmo.

Also, have another leaking fuel injector issue which proves there are some less than legitimate fuel injector rebuilders selling inferior products. The rig surges when driving at about 2000 rpms. Last time, had to change oil and add anti-Stiction additive. So...

I am thinking it is time for a complete upper end rebuild. Meaning, replace the heads - wondering about O-ringed vs regular??? New head gaskets - almost too much info on these... Installing studs, replacing injectors with motorcraft, new HPOP with upgrade, new oil cooler, replace FICM w harness, 6.4 push rods and banjo bolts, and a little turbo work. Curious if I should get a fuel return system?

It already has a hi-volume water pump, EGR delete, blue spring kit, and glow plugs. The rig sits some but I use it to pull a horse trailer through the mountains and jaunts when a full size rig is needed. And it is a manual. Had codes P0603 and P132B.

I realize this is a big job and don't know if I can do it myself as the local shops say it is between 36 and 40 shop hours. I really like to do my own work but the bulk of this is difficult for one fella, so I am saving money and leaning toward hiring it out. I think this would take me 10 plus days in an open door shop if I did it myself.

That is the initial plan, what wisdom can you share?

Ken

For me I take it in to my diesel guy. I don't have the time, tools or knowledge. Plus, I usually end up botching something and gotta have it done anyway. Money ahead. Without the Ford scanning software it can be chasing one part after another. My hat's off to the guys who can do it all on their own. I would contact Edge. Maybe there is something they can do to restore your Juice.

IMO the stock fuel system is fine. No need for a regulated return system (other than the OEM regulated return system) unless you have some high horsepower (ie larger injectors).

If you don't mind posting it, whose injectors did you get (because I TOTALLY agree with your assessment that there are quite a few rebuilders doing poor work).

I would HIGHLY recommend the DieselSite (slightly higher than stock capacity) upgraded HPOP. Expensive, but worth it.

What coolant are you running?
What is the temperature differential between oil and coolant (at normal highway speeds and when towing a heavy load)?

If you stll have Ford Gold coolant, then I would flush it thoroughly and switch to an EC-1 rated ELC coolant. How you flush it depends on whether or not the system is plugged up (and by how much).

If you have a clean coolant system, and your current oil cooler isn't plugged up, then going back with an OEM oil cooler isn't a bad decision. That said, if there is ANY indication of the oil cooler being plugged (even slightly), then I would recommend installing the remote oil cooler package from BulletProofDiesel.

Definitely get o-ringed heads.

KillDevilDiesel is coming out with re-designed aluminum heads that have some interesting upgrades. That said, I don't think I am adventurous enough to go with aluminum heads. Not until they have been proven.

I do like the FelPro head gaskets.

Personally, I do not think that much is gained with different banjo bolts.

I would HIGHLY recommend a fuel pressure sensor and gauge. Low fuel pressure is a COMMON cause of failed injectors.

Lastly, I would replace the heater hoses while you have good access to them.

Sorry for the delay, as a wildland firefighter, I get pulled away on assignments. And I appreciate your input. Here is what I know/learned from the above questions.

Edge really wouldn't work with me on my old system but in my research, so I purchased a new Edge CTS3 and plan to install it this weekend and see how it functions. Included the Exhaust Gas Temp add-on and think will add their fuel pressure system after this job is complete.

The existing coolant is Motorcraft Orange (VC-3DIL-B) with some anti-cavitation fluid. The deltas are about 10 degrees warmer on the engine oil under normal load, haven't pulled much of a load in a while to say; but the temps are about in the low/mid 180s coolant and 190's oil. Also have installed a cheap coolant filter. The coolant is 2 years old with 12,000 miles and looks really good, I would call it clean on visual appearance. Is this coolant considered extended life?


The failing injectors came from DCP. I am planning on replacing them with stock motorcraft fuel injectors, any better suggestions?

Looking at the total budget for my 'rebuild', the suggested HPOP might push me over but what do you think of a Bosch pump? I also need to purchase an oil cooler, FICM, and a replacement injector wiring harness. Should I purchase an oil cooler from the DieselSite? And what FICM do you recommend?

Have taken ownership of o-ringed heads, mahle gaskets, and ARP studs.

Working on finding a shop I trust as I am a 40 year shade tree mechanic with trust issues as I can do most of the work but do not have time or facility to lift the cab. It is also going to be $3500 plus in labor for work I LIKE to do... But my time is premium with the fire season raging, it is smart to have it done by someone else.

OK - my priorities are:
Find a shop and get the work scheduled.
Purchase the HPOP, oil cooler, fuel injectors, FICM, wiring harness, pushrods, and lesser items like bolts, hoses, coolant.

Your thoughts?

Ken

The OEM oil cooler seems to do the job just fine as long as the coolant isn't plugging it up. I have the Zerex GO5 in mine with a coolant filter system. Remanned FICM and injectors from Motorcraft seem to work well, too. My experience has been good. Some aftermarket parts just don't hold up well with the 6.0. If you were in my area have a great diesel guy that I trust completely.

Highly suggest going with Cat heavy duty ELC coolant.

https://peterbiltparts.com/2388647?campaign={campaign}&adgroup={adgroup}&keyword=&gclid=EAIaIQobChMIoYmWgKH08gIVX21vBB3fYg0EEAQYAiABEgLGw_D_BwE

Shell makes several Rotella ELC heavy duty coolants that are ok also.

You can not pick a coolant based on color. That said, the Ford ORANGE copolant is not meant for the 6.0L. Maybe it will do fine with a healthy dose of SCA, but I wouldn't want to try it. The Ford Orange is a type of DexCool. That type of coolant does not protect the 6.0L system well enough.

As stated above, I think the OEM oil cooler is fine if the coolant system is clean. Your temperatures indicate that your system might be clean. I like data instead of descriptions. IMO if you EVER get close to a 15 degree difference between coolant and oil temps (in a completely warmed up engine), then you have SOME plugging going on in the oil cooler.

I am not a fan of Bosch HPOPs, but who knows how they are being rebuilt now days. Same with the OEM remanufactured HPOPs. Some people have used them and they seem ok, some have used them and had issues. Who knows how long any of them will last, but IMO the Dieselsite HPOP will give you all the longevity you could want.

My personal choice would ONLY be an HPOP from Dieselsite or CNCFab.

CircuitBoardMedics will upgrade your own FICM for a reasonable price. I would go that route.

https://circuitboardmedics.com/search-results/?q=ficm

I like FICMRepair.com also - but they are expensive.

I would get the oil cooler from AutoNation White Bear Lake. They have GREAT prices. I would also get Ford remanufactured injectors from them, OR get some from Holders Diesel or Full Force Diesel.

03 injector part number:
3C3Z-9E527-ECRM

https://parts.autonationfordwhitebe...a-refundable-180-00-core-charge-3c3z9e527ecrm

https://holdersdiesel.com/collections/6-0-powerstroke-premium-fuel-injectors

https://shop.fullforcediesel.com/injectors-6-0-s/162.htm

OEM oil cooler (I would not buy this from anyone EXCEPT a dealership, like ANWBL). Part # 3C3Z-6A642-CA.

https://parts.autonationfordwhitebe...0-l-engine-oil-cooler-rebuild-kit-3c3z6a642ca

As a follow-up and closure... we did a complete top end rebuild.

Meaning, new heads (o-ringed), MAHL gaskets, ARP head Studs, FoMoCo rebuild fuel injectors, new Adrenalin HPOP, new coolant oil cooler, new FoMoCo injector wiring harness, rebuilt FICM, new FoMoCo IPC & IPR, 6.4 pushrods, upgraded 6.4 banjo bolts, new rear fuel crossover, new blue spring kit, upgraded egr delete, replaced the radiator hoses, turbo clean, and replaced the old Edge Juice Attitude with the CTS3. There are probably a few other things I cannot remember which were checked, cleaned, replaced, or tweaked.

It now runs like new after all of the air left the system. This means I did not figure out what the problems with my engine were as I replaced about everything. This summer, I will replace the turbo with a stage 1 'screamer' model. My latest challenge is to figure out what is the best programming to use on the CTS3 and purchase a fuel pressure sensor to add to the system.

The cost for parts and labor was probably around $7500, as I did hire out this job with a small local shop who could pull the cab (where I could not) and has more experience trouble shooting these things. I am very pleased with the way it runs and have 1000 miles on it now.

Also, there wasn't anything in my fuel tank as suggested to check for 'growth', just clean fuel. I use a coffee filter on an arm to swab around and looked at the pick up assembly for contamination - it was all 'clean'.

Thanks to everyone who helped provide input with my vehicle challenges, I appreciate this forum and the people who feed it.

Ken (MuleMan/6BarJ), NW Wyo territory

Sounds like a very nice truck. Glad you are "back in business"!

MuleMan said:

As a follow-up and closure... we did a complete top end rebuild.

Meaning, new heads (o-ringed), MAHL gaskets, ARP head Studs, FoMoCo rebuild fuel injectors, new Adrenalin HPOP, new coolant oil cooler, new FoMoCo injector wiring harness, rebuilt FICM, new FoMoCo IPC & IPR, 6.4 pushrods, upgraded 6.4 banjo bolts, new rear fuel crossover, new blue spring kit, upgraded egr delete, replaced the radiator hoses, turbo clean, and replaced the old Edge Juice Attitude with the CTS3. There are probably a few other things I cannot remember which were checked, cleaned, replaced, or tweaked.

It now runs like new after all of the air left the system. This means I did not figure out what the problems with my engine were as I replaced about everything. This summer, I will replace the turbo with a stage 1 'screamer' model. My latest challenge is to figure out what is the best programming to use on the CTS3 and purchase a fuel pressure sensor to add to the system.

The cost for parts and labor was probably around $7500, as I did hire out this job with a small local shop who could pull the cab (where I could not) and has more experience trouble shooting these things. I am very pleased with the way it runs and have 1000 miles on it now.

Also, there wasn't anything in my fuel tank as suggested to check for 'growth', just clean fuel. I use a coffee filter on an arm to swab around and looked at the pick up assembly for contamination - it was all 'clean'.

Thanks to everyone who helped provide input with my vehicle challenges, I appreciate this forum and the people who feed it.

Ken (MuleMan/6BarJ), NW Wyo territory

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Wondering how the last 6-8 months have treated you!?