93-94 ENGINE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 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INTRODUCING 7.3L IDI TURBOCHARGED DIESEL ENGINE INTRODUCTION7.3L IDI TURBOCHARGED DIESEL ENGINE F-SERIES The 7.3L IDI Turbocharged Diesel Engine will be optional in the F-Series trucks 37.3L IDL TURBOCHARGED DIESEL ENGINE The purpose of this publication i supplement aveieble 7-9 7.3L-7.3L IDI TURBOCHARGED DIESEL jesel Engine service literature and to introduce he 7.3L IDI ENGINE COMPARISON OVERVIEW Turbocharged Diesel Engine highlighting the following areas: ROWER ANDITQRGUE: CURVES *7.3L-7.SL IDI Turbocharged rae) Diesel Engine Comparison Overview 7.3L IDI TURBOCHARGED DIESEL — Power and Torque ENGINE PHYSICAL IDENTIFICATION —Spectfications — VEHICLE * 7.3L IDI Turbocharged Diesel Engine Physical Identification Vehicle —Engine * Engine Internal Changes — ENGINE ENGINE INTERNAL CHANGES PERFORMANCE DIAGNOSTICS GLEN =i Ue NT) Ges eee INTERCHANGEABILITY ¢ Performance Diagnostics A)" (ola) * Parts Identification and eaten Interchangeabilty * Service Tips — 7.3L IDI TURBOCHARGED DIESEL —7.3L Engines ENGINE —7'31 IDI Turbocharged Diesel Engines 7.3L DIESEL ENGINE UPDATE + 7.3L Diesel Engine Update — IMPROVEMENTS SINCE LAST — Improvements Since Last UPDATE (SEPTEMBER 1987) Nesin (epee S27}TURBOCHARGER BASIC FLOW AND THEORY rh irra 1 SS cre rt) Eg Panta anirouo rie Toa} 7.3L IDI eran A turbocharger is a relatively simple air pump used to increase the volume and density of air available for combustion in an engine. turbocharger consists of a turbine, which is driven by exhaust gases exiting the engine. This turbine is attached to the compressor by a common shaft supported by two bushings. Turbocharger operation raises the pressure delivered to the combustion chamber. This increase in air pressure presented to the combustion chamber with the properly metered quantity of fuel results in an increase in engine performance and efficiency. This feature will allow the engine to deliver rated levels of performance, irrespective of atmospheric conditions up to 10,000 feet elevation.TURBOCHARGER TURBOCHARGER WASTEGATE ACTUATOR COMPRESSOR (COLD) WHEEL at in) WASTEGATE os COMPRESSOR // HOUSING ms mast (HOT) WHEEL HOUSING LEGEND * DARK BLUE COMPRESSED AIR ARK RED =— EXHAUST INLET *LIGHT RED =— EXHAUST OUTLET © WHITE — WASTEGATETURBOCHARGER TURBOCHARGER LUBRICATION Ol. SUPPLY BEARINGS LEGEND * GREEN — OIL SUPPLY * YELLOW — RETURN OIL7.3L IDI TURBOCHARGED DIESEL ENGINE POWER CURVE COMPARISON The 7.3L IDI Turbocharged Diesel Engine will consistently deliver 190 hp at 3000 rpm rated speed up to elevations of 10,000 feet. Pa Dee CoC as TORQUE CURVE COMPARISON The 7.3L IDI Turbocharged Diesel Engine produces a peak torque of 388 Ib./it. at 1400 R.P.M. compared to the 7.3 naturally aspirated’s 338 Ib./I. on 1988-1992 engines and 358 Ib.ift. on 19927 engines * The 7.3L IDI Turbocharged Diesel Engine provides a significant increase in performance, altitude compensation and torque capability without sacrificing reliability of the drive train components a erat * A natural aspirated engine suffers a 3% loss of power per 1,000 feet of elevation above sea level * A 185 hp engine at 6,000 feet has a 33 hp loss of power * Some engine manufacturers also advertise a loss of power for every 1,000 feet of elevation above 5,000 feet on their turbocharged engines EA SMe ae UCT