1993-1994 Ford 7.3 IDI Turbocharged Diesel Engine Manual – PDF DOWNLOAD
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1993-1994 Ford 7.3 IDI Turbocharged Diesel Engine Manual – PDF DOWNLOAD
FOREWORD
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 contained 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 vehicles,
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:
1993-1994 Ford 7.3 IDI Turbocharged Diesel Engine Manual – PDF DOWNLOAD
INTRODUCTION 2
OPTIONAL INF-SERIES TRUCKS 3
7 3L-7 3L IDI TURBOCHARGED COMPARISON 4
TURBOCHARGER BASIC FLOW & THEORY 5
TURBOCHARGER LEGEND 6
TURBOCHARGER LUBRICATION LEGEND 7
POWER CURVE COMPARISON 8
TORQUE CURVE COMPARISON 8
SPECIFICATIONS CHART 9
PHYSICAL IDENTIFICATION 10
Engine Serial Number 10
Calibration Label 10
Emissions Label 1 O
EXTERNAL FEATURES 11
AIR CLEANER ASSEMBLY 11
TURBOCHARGER ASSEMBLY 11
EXHAUST CROSSOVER PIPE
TURBOCHARGER PACKAGE
TURBOCHARGER ASSEMBLY
TURBOCHARGER ID PLATE 13
A/RRATIO 14
TURBINE A/R RATIO 14
CROSSOVER PIPE 15
“Y” COLLECTOR 15
EXHAUST INLET CASTING 15
WASTEGATE 16
WASTEGATE ACTUATOR
MARMON CLAMP
PEDESTAL
AIR CHAMBER 18
OIL MANIFOLD 18
TURBOCHARGER OIL SUPPLY 18
TURBOCHARGER OIL LINE 19
HEAT SHIELDING
TURBINE/EXHAUST HEAT SHIELD
AIR CLEANER ASSEMBLY 20
AIR CLEANER ELEMENT 20
FILTER MINDER 20
VALVE COVERS 21
LEFT VALVE COVER 21
RIGHT VAL VE COVER
ENGINE WIRING HARNESS
DESIGN MODIFICATIONS
INTERNAL PARTS CHANGES
Head Gasket
Turbocharged Power Cylinder Components 24
Connecting Rod 24
Piston Pin 25
Anodized Piston Head 25
Piston Rings Keystone Design 25
Ring Groove Measurement 26-27
Exhaust Valve 27
EXTERNAL MODIFICATIONS 27
Oil Cooler Bundle 27
Flywheel 28
Vibration Damper 28
Fuel Injection Pump 28-29
Fuel Injection Nozzle 29
Fuel Return Line 29
TURBOCHARGED ENGINE DIAGNOSTICS 30
DIAGNOSTIC FORMS
DIAGNOSTIC CHANGES
BOOST TEST 30-32
WASTEGATE ACTUATOR TEST 32·34
AIR FILTER RESTRICTION TEST 34-35
INJECTION PUMP TIMING TEST 35
INJECTION PUMP TIMING 35
INJECTION PUMP TRANSFER PRESSURE TEST 36-37
NOZZLE TEST 38
CRANKCASEPRESSURETEST 38-40
SERVICE TIPS
TURBO REMOVAL 41 -46
TURBO INSPECTION 46
Check End Play 46
Check Radial Movement 46
TURBO COMPONENT REPLACEMENT 47
Center Section Replacement 47-51
Wastegate Actuator Removal
Wastegate Actuator Installation
Turbo Installation
Injection Pump Removal
Injection Pump Installation
Torque Angle
Test Air Induction
CHASSIS CHANGES
BUMPER SLOTS
AIR DAM 66
E40D DIPSTICK 66
E40D MICROPROCESSOR 66
EXHAUST SYSTEM
FAN CLUTCH
APPENDIX
SERIAL NUMBER BREAK LISTING
ENGINE PERFORMANCE CHART
DIAGNOSTIC GUIDE
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