93-94
ENGINEFOREWORD
This publication is intended to provide technicians and service personnel with the latest technical
advancements incorporated in the 7.3L IDI Turbocharged Diesel Engine. The information con-
tained in this publication will supplement information contained in available service literature.
IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable
operation of all motor vehicles, as well as the personal safety of the individual doing the work.
This manual provides general directions for accomplishing service and repair work with tested,
effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts for servicing vet
‘as well as in the skill of the individual doing the work. This manual cannot possibly anticipate
all such variations and provide advice or cautions as to each. Accordingly, anyone who departs
from the instructions provided in this manual must first establish that he comprises neither
his personal safety nor the vehicle integrity by his choice of methods, tools or parts.
The following list contains some general WARNINGS that you should follow when you work
on a vehicle.
+ Always wear safety glasses for eye protection.
* Use safety stands whenever a procedure requires you to be under the vehicle.
* Be sure that the ignition switch is always in the OFF position, unless otherwise required
by the procedure.
+ Never perform any service to the engine with the air cleaner removed and the engine running
unless a turbocharger compressor inlet shield is installed. Reference instructions on page 36.
* Set the parking brake when working on the vehicle. If you have an automatic transmission,
set it in PARK unless instructed otherwise for a specific service operation. If you have a
manual transmission, it should be in REVERSE (engine OFF) or NEUTRAL (engine ON)
unless instructed otherwise for a specific service operation.
* Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide.
+ Keep yourself and your clothing away from moving parts when the engine is running,
especially the fan, belts, and the turbocharger compressor.
* To prevent serious burns, avoid contact with hot metal parts such as the radiator, turbocharger
pipes, exhaust manifold, tail pipe, catalytic converter and muffler
* Do not smoke while working on the vehicle.
* To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing
before beginning to work on a vehicle. Tie long hair securely behind the head.
* Keep hands and other objects clear of the radiator fan blades.TABLE OF CONTENTS.
7.3 LITER IDI TURBOCHARGED DIESEL ENGINE
INTRODUCTION.
OPTIONAL IN F'SERIES TRUCKS:
7.3L-7.31 IDI TURBOCHARGED COMPARISON
TURBOCHARGER BASIC FLOW & THEORY
TURBOCHARGER LEGEND
TURBOCHARGER LUBRICATION LEGEND
POWER CURVE COMPARISON
TORQUE CURVE COMPARISON
SPECIFICATIONS CHART
PHYSICAL IDENTIFICATION
Engine Serial Number
Calibration Label
Emissions Label
EXTERNAL FEATURES
AIR CLEANER ASSEMBLY.
TURBOCHARGER ASSEMBLY
EXHAUST CROSSOVER PIPE
‘TURBOCHARGER PACKAGE.
TURBOCHARGER ASSEMBLY
TURSOCHARGER ID PLATE
AIR RATIO.
TURBINE AIR RATIO.
CROSSOVER PIPE
"Y" COLLECTOR
EXHAUST INLET CASTING
WASTEGATE
WASTEGATE ACTUATOR
MARMON CLAMP
PEDESTAL,
AIR CHAMBER
OL MANIFOLD
TURBOCHARGER OIL SUPPLY
TURBOCHARGER OIL LINE
HEAT SHIELDING
TURBINEIEXHAUST HEAT SHIELD
AIR CLEANER ASSEMBLY
AIR CLEANER ELEMENT.
FILTER MINDER
VALVE COVERS
LEFT VALVE COVER,
RIGHT VALVE COVER,
ENGINE WIRING HARNESS
DESIGN MODIFICATIONS.
INTERNAL PARTS CHANGES
Head Gasket
1"
u
"
1
12
13
13
4
4
18
18
15
16
16
16
7
18
18
18
19
19
19
20
20
20
a
Fl
21
22
23
2a
28
Turbocharged Power Cylinder Components
Connecting Rod
Piston Pin
‘Anodized Piston Had
Piston Rings Keystone Design
Ring Groove Measurement
Exhaust Valve
EXTERNAL MODIFICATIONS
Ol Cooter Buncte
Flywheel
\ioration Damper
Fuel Injection Pump
Fue! Injection Nozzle
Fuel Return Line
‘TURBOCHARGED ENGINE DIAGNOSTICS.
DIAGNOSTIC FORMS.
DIAGNOSTIC CHANGES
BOOST TEST
WASTEGATE ACTUATOR TEST
AIR FILTER RESTRICTION TEST.
INJECTION PUMP TIMING TEST
INJECTION PUMP TIMING.
INJECTION PUMP TRANSFER PRESSURE TEST
NOZZLE TEST
CRANKCASE PRESSURE TEST
SERVICE TIPS.
TURBO REMOVAL
‘TURBO INSPECTION
Cheek End Play
Check Radial Movement
‘TURBO COMPONENT REPLACEMENT
Center Section Replacement
Weastegate Actuator Removal
Wastegate Actuator Installation
Turbo installation
Injection Pump Removal
Injection Pump Installation
Torque Angle
Test Air Induction
CHASSIS CHANGES.
BUMPER SLOTS
AIR DAM
E400 DIPSTICK
40D MICROPROCESSOR
EXHAUST SYSTEM
FAN CLUTCH
APPENDIX
SERIAL NUMBER BREAK LISTING
ENGINE PERFORMANCE CHART
DIAGNOSTIC GUIDE
Page
24
24
25
25
25
26-27
27
27
or
28
28
28.29
20
29
30
30
30
5032
32.04
34.35
35
35
3637
38
38-40
40
41-48
46
46
46
a7
47st
5152
5354
5459
59.60
60
61-63
63.65
65
65
66
er
er
Al
a2