Ford Power Stroke engine
Encyclopedia
Power Stroke is the name given to the diesel engines found in Ford Super Duty
trucks, Ford Excursion SUVs, Ford Econoline vans, and Ford LCF commercial vehicles. Production by Navistar International Corporation (International Truck and Engine Corporation) for Ford Motor Company
began in mid 1994, in Indianapolis, Indiana
, Huntsville, Alabama
, and Brazil
and continued until 2010. The Navistar sourced diesels came in displacements of 7.3, 6.9, 6.0, 4.5, and 6.4 liters. In the middle of 2010 Ford released a newly designed 6.7 Liter Powerstroke engine (codenamed the Scorpion and built in house by Ford) along with a newly redesigned interior and exterior and for the first time since the Powerstroke first appeared in 1994 there was no manual transmission offered.
These engines primarily compete in the United States full-size pickup truck
market with the Duramax V8
from General Motors
/Isuzu
DMAX and the B series
straight 6 from Dodge
/Cummins
.
IDI
(from Indirect Injection) engine is a 4-stroke V-8 Diesel
engine used in International trucks and Ford F-Series
pickups from 1982 to 1994. The engine had two displacements: 420 cubic inches (6.9 litres), which was used in Ford trucks from 1983 to 1987, and 444 cubic inches (7.3 litres), which was used in Ford trucks from 1987 to 1993 (naturally aspirated
). The turbo charged version was to be a single year stopgap as production of the new Power Stroke engine was to debut with the 1994 model year. (turbocharged
). Production of the 7.3 Turbo IDI engine was extended to mid-year 1994 as the new engine was not ready in time for a full 1994 model year run. The turbo 7.3 was very similar to the previous 6.9l and 7.3l IDI diesel engines. They differed in that the 7.3 IDI Turbo had different wrist pins, piston rings, as well as different flow capacity fuel injectors. Additionally, the fuel injection pump output was slightly increased to compensate for the additional air charge. This engine was replaced in mid 1994 by the Navistar T444E (7.3L) engine. The 6.9 IDI, 7.3 IDI, and 7.3 IDIT engines are not in the Power Stroke family.
As of 1994 during the middle of the 1994 year model production 7.3 litre Diesel and 7.3 litre Power Stroke Turbo Diesel became on option until the end of the 1994 year model production.
, with fuel cutoff at 4200 rpm, but having a redline of 4500 rpm only attainable with aftermarket performance programming.
Some of the 6.0 L Power Stroke engines have proven to be problematic, and speculated to have cost Ford millions of dollars in warranty repairs and buy backs. They led to many recalls and the repurchase of at least 500 trucks, particularly in the first year. However, aftermarket parts (e. g. redesigned EGR coolers) exist to address these issues and, with them installed, the 6.0L engine's reliability improves greatly.
valves, restricted oil coolers, which lead to leaking EGR coolers.
engines). By contrast, the 6.0 only has 4 head bolts per cylinder.
recalibrations, fuel injector stiction along with several other driveability and QC issues have been issues for the 6.0 as well.
The new engine has a 3.86 in (98 mm) bore and 4.13 in (105 mm) stroke, resulting in a total calculated displacement of 387 cu in (6.3 l) or (6333 cc). Despite having to meet emission regulations, the new engine was able to increase horsepower and torque ratings to 350 hp and torque to 650 lbft at the flywheel. Horsepower and torque are achieved at 3,000 rpm and 2,000 rpm respectively. It also features a dual sequential turbo system. The main components of this system are a smaller, non-wastegated turbo providing boost to a larger variable geometry turbo. This system is designed to result in reduced turbo "lag" when accelerating from a stop. The series-turbo system is set up to provide a better throttle response while in motion to give a power flow more like a Naturally aspirated engine. The 6.4 liter also has a Diesel Particulate Filter
(DPF) and dual EGR coolers which are capable of reducing exhaust gas temps by up to 1000 degrees before they reach the EGR valve and mixed in with the intake charge. The Diesel Particulate filter traps soot and particulates from the exhaust and virtually eliminates the black smoke that most diesel engines expel upon acceleration. The engine computer is programmed to periodically inject extra fuel (known as a "regeneration" in F-Series) to burn off soot that accumulates in the DPF. This engine must run on Ultra Low Sulfur Diesel (ULSD) fuel which has no more than 15 ppm sulfur content; using regular diesel fuel will result in emission equipment malfunctions and violate manufacturer warranties.
The 6.4L has had one recall (Safety product recall
07S49 was released on March 23, 2007) that addresses the potential for flames to come from the tailpipe of the truck. This problem arises from the DPF which is part of the diesel after-treatment system. A PCM recalibration has been released to eliminate the possibility of excessive exhaust temperatures combined with certain rare conditions resulting from what is becoming known as a "Thermal Event".
. During design, Ford engineers codenamed this engine "Scorpion" due to the turbo being mounted right on top of the block. It includes a Compacted graphite iron
(CGI) block for greater strength while reducing weight, reverse flow aluminum cylinder heads (the exhaust ports are located in the lifter valley) with dual water jackets, six head bolts per cylinder, and 29000 psi (1,999 bar) a high-pressure common rail Bosch fuel system. The system delivers up to five injection events per cylinder per cycle using eight-hole piezo injectors spraying fuel into the piston bowl. This engine also supports B20 biodiesel (allowing greener fueling options of up to 20 percent biodiesel and 80 percent petroleum diesel). There is also a unique inboard exhaust and outboard intake architecture, an automotive-industry first for a modern production diesel engine. Honeywell’s single-sequential turbocharger features an industry-first double-sided compressor wheel mounted on a single shaft. It combines the benefits of a small turbocharger (faster response) and a large turbocharger (ability to compress and force more air into the engine for more power) in one unit. The connecting rods are made by Mahle
.
Emissions controls include exhaust gas recirculation, Denoxtronic based Selective Catalytic Reduction
(SCR) solution from Bosch, and a Diesel Particulate Filter
(DPF). Output was originally 390 hp and 735 lbft. but shortly after production started, Ford announced that they have made an update to the new 6.7L diesel. The new engine control software makes the engine capable of 400 hp @ 2800 rpm and 800 lbft @ 1600 rpm while achieving better fuel economy and without any physical changes to the engine. All 6.7L engines already shipped to dealerships or purchased by customers can be upgraded to Fords new specifications with a free software update available at Ford dealerships.
F-Series Super Duty/Excursion Applications
E-Series Applications
LCF (Low Cab Forward) Application
Ford Super Duty
For the 1999 model year, Ford shifted the F-250 and F-350 truck lines to a design mechanically and cosmetically distinct from that of the F-150. The F-350 was not available for 1998, while the F-250 was available that year with the F-150's body...
trucks, Ford Excursion SUVs, Ford Econoline vans, and Ford LCF commercial vehicles. Production by Navistar International Corporation (International Truck and Engine Corporation) for Ford Motor Company
Ford Motor Company
Ford Motor Company is an American multinational automaker based in Dearborn, Michigan, a suburb of Detroit. The automaker was founded by Henry Ford and incorporated on June 16, 1903. In addition to the Ford and Lincoln brands, Ford also owns a small stake in Mazda in Japan and Aston Martin in the UK...
began in mid 1994, in Indianapolis, Indiana
Indianapolis, Indiana
Indianapolis is the capital of the U.S. state of Indiana, and the county seat of Marion County, Indiana. As of the 2010 United States Census, the city's population is 839,489. It is by far Indiana's largest city and, as of the 2010 U.S...
, Huntsville, Alabama
Huntsville, Alabama
Huntsville is a city located primarily in Madison County in the central part of the far northern region of the U.S. state of Alabama. Huntsville is the county seat of Madison County. The city extends west into neighboring Limestone County. Huntsville's population was 180,105 as of the 2010 Census....
, and Brazil
Brazil
Brazil , officially the Federative Republic of Brazil , is the largest country in South America. It is the world's fifth largest country, both by geographical area and by population with over 192 million people...
and continued until 2010. The Navistar sourced diesels came in displacements of 7.3, 6.9, 6.0, 4.5, and 6.4 liters. In the middle of 2010 Ford released a newly designed 6.7 Liter Powerstroke engine (codenamed the Scorpion and built in house by Ford) along with a newly redesigned interior and exterior and for the first time since the Powerstroke first appeared in 1994 there was no manual transmission offered.
These engines primarily compete in the United States full-size pickup truck
Pickup truck
A pickup truck is a light motor vehicle with an open-top rear cargo area .-Definition:...
market with the Duramax V8
Duramax V8 engine
The Duramax is General Motors diesel engine family for light- and medium-duty trucks, designed by General Motors. The 6.6 liter Duramax is produced by DMAX, a joint venture between GM and Isuzu in Moraine, Ohio. This engine was initially installed in 2001 model year Chevy and GMC trucks and has...
from General Motors
General Motors
General Motors Company , commonly known as GM, formerly incorporated as General Motors Corporation, is an American multinational automotive corporation headquartered in Detroit, Michigan and the world's second-largest automaker in 2010...
/Isuzu
Isuzu
, is a Japanese car, commercial vehicle and heavy truck manufacturing company, headquartered in Tokyo. In 2005, Isuzu became the world's largest manufacturer of medium to heavy duty trucks. It has assembly and manufacturing plants in the Japanese city of Fujisawa, as well as in the prefectures...
DMAX and the B series
Cummins B Series engine
The Cummins B Series is a family of straight-four and straight-6 diesel truck and industrial piston engines manufactured by Cummins. The B Series is known for displacing "one liter per cylinder" because of the popular straight-four and straight-six. A straight-four is also available...
straight 6 from Dodge
Dodge
Dodge is a United States-based brand of automobiles, minivans, and sport utility vehicles, manufactured and marketed by Chrysler Group LLC in more than 60 different countries and territories worldwide....
/Cummins
Cummins
Cummins Inc. is a Fortune 500 corporation that designs, manufactures, distributes and services engines and related technologies, including fuel systems, controls, air handling, filtration, emission control and electrical power generation systems...
.
International 6.9l/7.3l IDI
The International HarvesterInternational Harvester
International Harvester Company was a United States agricultural machinery, construction equipment, vehicle, commercial truck, and household and commercial products manufacturer. In 1902, J.P...
IDI
International Harvester IDI
The International Harvester IDI engine is a 4-stroke 8-cylinder Diesel engine used in International Harvester trucks and Ford F-Series pickups from 1982 to 1994...
(from Indirect Injection) engine is a 4-stroke V-8 Diesel
Diesel engine
A diesel engine is an internal combustion engine that uses the heat of compression to initiate ignition to burn the fuel, which is injected into the combustion chamber...
engine used in International trucks and Ford F-Series
Ford F-Series
The F-Series is a series of full-size pickup trucks from Ford Motor Company which has been sold continuously for over six decades. The most popular variant of the F-Series is the F-150...
pickups from 1982 to 1994. The engine had two displacements: 420 cubic inches (6.9 litres), which was used in Ford trucks from 1983 to 1987, and 444 cubic inches (7.3 litres), which was used in Ford trucks from 1987 to 1993 (naturally aspirated
Naturally-aspirated engine
A naturally aspirated engine is one common type of reciprocating piston internal combustion engine that depends solely on atmospheric pressure to counter the partial vacuum in the induction tract to draw in combustion air...
). The turbo charged version was to be a single year stopgap as production of the new Power Stroke engine was to debut with the 1994 model year. (turbocharged
Turbocharger
A turbocharger, or turbo , from the Greek "τύρβη" is a centrifugal compressor powered by a turbine that is driven by an engine's exhaust gases. Its benefit lies with the compressor increasing the mass of air entering the engine , thereby resulting in greater performance...
). Production of the 7.3 Turbo IDI engine was extended to mid-year 1994 as the new engine was not ready in time for a full 1994 model year run. The turbo 7.3 was very similar to the previous 6.9l and 7.3l IDI diesel engines. They differed in that the 7.3 IDI Turbo had different wrist pins, piston rings, as well as different flow capacity fuel injectors. Additionally, the fuel injection pump output was slightly increased to compensate for the additional air charge. This engine was replaced in mid 1994 by the Navistar T444E (7.3L) engine. The 6.9 IDI, 7.3 IDI, and 7.3 IDIT engines are not in the Power Stroke family.
As of 1994 during the middle of the 1994 year model production 7.3 litre Diesel and 7.3 litre Power Stroke Turbo Diesel became on option until the end of the 1994 year model production.
7.3 Power Stroke
In mid 1994, the 7.3L Power Stroke diesel was introduced. Although the previous 7.3L had the same displacement, there weren't any other similarities between the two. The Power Stroke is an electronically controlled, direct injection engine with a 4.11 in (104 mm) bore and 4.18 in (106 mm) stroke creating a displacement of 444 cu in (7.3 l). It has a 17.5:1 compression ratio, and has a dry weight of approximately 920 lbs. This engine produced up to 250 hp and 505 lbft of torque in automatic trucks during the last years of production, and 275 hp and 520 lbft of torque in manual trucks. The 1994.5 to 1996/97 DI Power stroke had "single shot" HEUI (hydraulically actuated electronic unit injection) fuel injectors and ran a 15° high pressure oil pump (HPOP) to create the necessary oil pressure to fire the fuel injectors. 1994.5-1997 trucks used a cam driven fuel pump, whereas the 1999-2003 trucks used a frame rail mounted electric fuel pump. The California trucks in 1996 and 1997 had split shot fuel injectors whereas the rest of the trucks didn't get split shots until 1999. The difference between the split shot and single shot are the single shot only injects one charge of fuel per cycle, whereas the split shot releases a pre light load before the main charge to initiate combustion in a more damped manner. This controlled injection helps reduce the sharp combustion 'knock'. It utilizes a single turbocharger with a turbine housing size of 1.15 A/R. In 1999, an air to air intercooler was added to cool the charged air from the turbo making it more dense. The cooler, denser air would increase the horsepower potential of the engine, while also reducing exhaust gas temperatures (EGTs). Eventually, the turbine housing was changed to a .84 A/R housing and a wastegate was added. With larger injectors, the HPOP was advanced to 17° to change fueling characteristics. The 7.3 L DI Power Stroke was in production until the middle of model year 2003 when it was replaced by the 6.0L.Key Specifications
- Fuel Injection System: HEUI (Hydraulic Electronic Unit Injectors)
- Valve Train: OHV 2-valve
- Turbo Configuration: Single Standard
6.0 Power Stroke
The 7.3 L (444 CID) Power Stroke was replaced by the 6.0 L (365 CID) midway through the 2003 model year. The 6.0L Power Stroke was used in Ford Super Duty trucks until the 2008 model year but lasted until 2009 in Ford Econoline vans (Model year 2010). The engine has a 3.74 in (95 mm) bore and 4.13 in (105 mm) stroke creating a displacement of 365 cu in (6 l) or 5954 cc. It utilizes a variable geometry turbocharger and intercooler, producing 325 hp and 570 lbft with an 18:1 compression ratioCompression ratio
The 'compression ratio' of an internal-combustion engine or external combustion engine is a value that represents the ratio of the volume of its combustion chamber from its largest capacity to its smallest capacity...
, with fuel cutoff at 4200 rpm, but having a redline of 4500 rpm only attainable with aftermarket performance programming.
Some of the 6.0 L Power Stroke engines have proven to be problematic, and speculated to have cost Ford millions of dollars in warranty repairs and buy backs. They led to many recalls and the repurchase of at least 500 trucks, particularly in the first year. However, aftermarket parts (e. g. redesigned EGR coolers) exist to address these issues and, with them installed, the 6.0L engine's reliability improves greatly.
Intake & Exhaust
Some of the problems encountered, was the possibility of the variable geometry turbo charger to stick due to carbon deposits and/or rust buildup. This could potentially cause over boost and under boost conditions, which could lead to headgasket failure. Other problems include sticking Exhaust gas recirculationExhaust gas recirculation
In internal combustion engines, exhaust gas recirculation is a nitrogen oxide emissions reduction technique used in petrol/gasoline and diesel engines. EGR works by recirculating a portion of an engine's exhaust gas back to the engine cylinders. In a gasoline engine, this inert exhaust...
valves, restricted oil coolers, which lead to leaking EGR coolers.
- Carbon deposits can be a issue with any engine with EGR, but had a tendency to lead to a Domino effectDomino effectThe domino effect is a chain reaction that occurs when a small change causes a similar change nearby, which then will cause another similar change, and so on in linear sequence. The term is best known as a mechanical effect, and is used as an analogy to a falling row of dominoes...
of issues for the 6.0.
Cylinder head
The major problem with the 6.0L was the torque-to-yield head bolts, which in an overboost condition would lead to a a blown head gasket, and eventually a cracked cylinder head. The 7.3 and 6.7 Power Stroke engines all have 6 head bolts per cylinder (as well as the 6.9 and 7.3 International Harvester IDIInternational Harvester IDI
The International Harvester IDI engine is a 4-stroke 8-cylinder Diesel engine used in International Harvester trucks and Ford F-Series pickups from 1982 to 1994...
engines). By contrast, the 6.0 only has 4 head bolts per cylinder.
Electrical
Numerous PCMEngine control unit
An engine control unit is a type of electronic control unit that determines the amount of fuel, ignition timing and other parameters an internal combustion engine needs to keep running...
recalibrations, fuel injector stiction along with several other driveability and QC issues have been issues for the 6.0 as well.
Key specifications
- Fuel Injection system: Split Shot HEUI (Hydraulic Electronic Unit Injectors)
- Valve Train: OHV 4-valve
- Turbo configuration: Single Variable Vane Geometry (VGT)
6.4 Power Stroke
The 6.4 L Power Stroke replaced the 6.0 L due to new emission regulations for on-highway diesel engines built after January 1, 2007; in early 2007 Ford introduced its redesigned 2008 Super Duty with the new 6.4 liter engine as an option.The new engine has a 3.86 in (98 mm) bore and 4.13 in (105 mm) stroke, resulting in a total calculated displacement of 387 cu in (6.3 l) or (6333 cc). Despite having to meet emission regulations, the new engine was able to increase horsepower and torque ratings to 350 hp and torque to 650 lbft at the flywheel. Horsepower and torque are achieved at 3,000 rpm and 2,000 rpm respectively. It also features a dual sequential turbo system. The main components of this system are a smaller, non-wastegated turbo providing boost to a larger variable geometry turbo. This system is designed to result in reduced turbo "lag" when accelerating from a stop. The series-turbo system is set up to provide a better throttle response while in motion to give a power flow more like a Naturally aspirated engine. The 6.4 liter also has a Diesel Particulate Filter
Diesel Particulate Filter
A diesel particulate filter is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine. Wall-flow diesel particulate filters usually remove 85% or more of the soot, and under certain conditions can attain soot removal efficiencies of close to 100%...
(DPF) and dual EGR coolers which are capable of reducing exhaust gas temps by up to 1000 degrees before they reach the EGR valve and mixed in with the intake charge. The Diesel Particulate filter traps soot and particulates from the exhaust and virtually eliminates the black smoke that most diesel engines expel upon acceleration. The engine computer is programmed to periodically inject extra fuel (known as a "regeneration" in F-Series) to burn off soot that accumulates in the DPF. This engine must run on Ultra Low Sulfur Diesel (ULSD) fuel which has no more than 15 ppm sulfur content; using regular diesel fuel will result in emission equipment malfunctions and violate manufacturer warranties.
The 6.4L has had one recall (Safety product recall
Product recall
A product recall is a request to return to the maker a batch or an entire production run of a product, usually due to the discovery of safety issues. The recall is an effort to limit liability for corporate negligence and to improve or avoid damage to publicity...
07S49 was released on March 23, 2007) that addresses the potential for flames to come from the tailpipe of the truck. This problem arises from the DPF which is part of the diesel after-treatment system. A PCM recalibration has been released to eliminate the possibility of excessive exhaust temperatures combined with certain rare conditions resulting from what is becoming known as a "Thermal Event".
Key Specifications
- Fuel Injection System: High Pressure Commonrail
- Valve Train: OHV 4-valve
- Dual sequential turbochargers
- Diesel particulate filter
6.7 Power Stroke
The 6.7 L is the first medium duty diesel designed and built by Ford. It was designed in conjunction with AVL in AustriaAustria
Austria , officially the Republic of Austria , is a landlocked country of roughly 8.4 million people in Central Europe. It is bordered by the Czech Republic and Germany to the north, Slovakia and Hungary to the east, Slovenia and Italy to the south, and Switzerland and Liechtenstein to the...
. During design, Ford engineers codenamed this engine "Scorpion" due to the turbo being mounted right on top of the block. It includes a Compacted graphite iron
Compacted graphite iron
Compacted graphite iron , also known as vermicular graphite iron especially in non-English speaking countries, is a metal which is gaining popularity in applications that require either greater strength, or lower weight than cast iron.R.D...
(CGI) block for greater strength while reducing weight, reverse flow aluminum cylinder heads (the exhaust ports are located in the lifter valley) with dual water jackets, six head bolts per cylinder, and 29000 psi (1,999 bar) a high-pressure common rail Bosch fuel system. The system delivers up to five injection events per cylinder per cycle using eight-hole piezo injectors spraying fuel into the piston bowl. This engine also supports B20 biodiesel (allowing greener fueling options of up to 20 percent biodiesel and 80 percent petroleum diesel). There is also a unique inboard exhaust and outboard intake architecture, an automotive-industry first for a modern production diesel engine. Honeywell’s single-sequential turbocharger features an industry-first double-sided compressor wheel mounted on a single shaft. It combines the benefits of a small turbocharger (faster response) and a large turbocharger (ability to compress and force more air into the engine for more power) in one unit. The connecting rods are made by Mahle
Mahle GmbH
Mahle GmbH is one of the 30 largest automotive suppliers worldwide. As the leading manufacturer of components and systems for combustion engines and its periphery, the Mahle Group is among the top three systems suppliers worldwide for piston systems, cylinder components, valve train systems, air...
.
Emissions controls include exhaust gas recirculation, Denoxtronic based Selective Catalytic Reduction
Selective catalytic reduction
Selective catalytic reduction is a means of converting nitrogen oxides, also referred to as with the aid of a catalyst into diatomic nitrogen , , and water, . A gaseous reductant, typically anhydrous ammonia, aqueous ammonia or urea, is added to a stream of flue or exhaust gas and is absorbed...
(SCR) solution from Bosch, and a Diesel Particulate Filter
Diesel Particulate Filter
A diesel particulate filter is a device designed to remove diesel particulate matter or soot from the exhaust gas of a diesel engine. Wall-flow diesel particulate filters usually remove 85% or more of the soot, and under certain conditions can attain soot removal efficiencies of close to 100%...
(DPF). Output was originally 390 hp and 735 lbft. but shortly after production started, Ford announced that they have made an update to the new 6.7L diesel. The new engine control software makes the engine capable of 400 hp @ 2800 rpm and 800 lbft @ 1600 rpm while achieving better fuel economy and without any physical changes to the engine. All 6.7L engines already shipped to dealerships or purchased by customers can be upgraded to Fords new specifications with a free software update available at Ford dealerships.
Key Specifications
- Fuel Injection System: High Pressure Commonrail
- Valve Train: OHV 4-valve
- Turbo configuration: Single Sequential Variable Vane Geometry (VGT)
- Diesel particulate filter
- Selective Catalytic Reduction
Applications
The Power Stroke engine has been used in the following applications.F-Series Super Duty/Excursion Applications
- Mid-1994–2003 7.3 L
- Mid2003–Mid2007 6.0 L
- 2008–2010 6.4 L
- 2011– 6.7 L
E-Series Applications
- Mid-1994–2003 7.3 L
- 2004–2009 6.0 L
LCF (Low Cab Forward) Application
- 2005–2009 4.5 L