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How We Permanently Fix The Ford 6 Liter Diesel

The Ford 6 liter diesel engine is fraught with numerous problems however all of these can be overcome. In this video we will show you what we feel is...

The Ford 6 liter diesel engine is fraught with numerous problems however all of these can be overcome. In this video we will show you what we feel is the ultimate repair solution for the 6 Liter: repairs that will keep the engine performing reliably for years and years.

Many of the 6 liters problems stem from the design of the engine and oil cooling systems. This engine uses a unique system in which the engine oil cooler is mounted inside the V of the engine. Here coolant flows through narrow passageways which eventually plug up causing coolant flow restrictions and excessive oil temperatures. From here coolant flows to the EGR cooler which, due to its narrow passageways also tends to clog. Excessive coolant temperatures eventually lead to head gasket failures and even a destroyed engine if left long enough.

For the truck shown in this video, the owner wisely chose to do the ultimate repair job; a repair which eliminates all the weaknesses of the 6 liter engine. This includes cylinder head studs to prevent future head gasket failures, a Bulletproof EGR cooler plus the bulletproof remote engine oil cooler system. A number of minor but nonetheless important upgrades were done during the procedure including new oil stand pipes and STC fitting on the high pressure oil pump.

Let’s get started:

First step is to remove the bumpers and accessories from the front of the truck then disconnect all items necessary to remove the cab from the vehicle. This includes evacuating the A/C system, draining the coolant, disconnecting the steering column, brake lines, coolant and  heater hoses, wiring and much more.

Once the cab is raised the engine is readily accessible and a pleasure to work on.

Stripping the engine down is our next step and the next few photos reveal just that, with the heads, oil cooler assembly and high-pressure oil pump removed.

The many dismantled parts can be seen in this enormous layout.

Next steps include cleaning components such as the block deck and cylinder head surfaces along with the oil pump cover and all of the many bolts and miscellaneous parts.

We are now ready to put things back together:

The high-pressure oil pump is reinstalled along with a new and improved STC fitting. On occasion the old STC fitting would break and when this occurred would crack the back of the engine block.

Following pump installation, the cover is installed and tightened down.

We next move onto installation of the Bulletproof remote oil cooler adapter: this is a complete assembly that bolts in place of the engine oil cooler and cover.

Cylinder head studs are installed, then head gaskets, then cylinder heads. Heads are torqued to spec. During head installation, fuel injectors are reinstalled with new seals, along with rocker arms and bridges.

Covering the valve gear sits the high-pressure oil manifold and installed along with this are the upgraded high-pressure oil standpipes. The original designed pipes and seals would fail resulting in a loss of oil pressure and an engine no start.

To ensure an easy start up the oil system is primed until oil flows from the manifold test port.

We’re now onto installing valve covers and the turbo stand

Next is the Intake manifold along with a Bulletproof EGR cooler, this component has been rebuilt to eliminate the causes of failure in the original cooler. Check out the differences between the Bulletproof’s large tubes and the original’s thin tubes: the durability looks very evident.

Some next installations include the oil and fuel filter adapters and plumbing. Because we are using the Bulletproof oil cooler system the original oil filter is no longer used.

Next comes the turbocharger, the FICM or fuel injection control module and the remaining wiring, hoses and sensors.

Here’s how it all looks from front and back, fully assembled and awaiting the cab to be remounted.

With the cab back down we can now work on installing the rest of the Bulletproof oil cooler system which includes first relocating the power steering cooler near the bottom of the radiator. We next install the cooler, pipes and hoses.

The remote oil filter is mounted behind the left front bumper bracket.

Final assembly requires reinstalling and reconnecting all other under hood components, then filling the cooling system, recharging the A/C and we are ready for start up.

After a successful start up, warm up and inspection for leaks our 6 liter Ford truck is ready to go for many miles of trouble free operation having had all major original design flaws corrected.

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