In the May '10 issue we showed you how to put a 7.3L Power Stroke together from the ground up and explained many of the tips and tricks involved in rebuilding one (including a forged connecting rod upgrade). This time, we're back to show you how to resurrect the 7.3L's successor, the 6.0L Power Stroke, using more genuine (and affordable) Ford parts. Ford's 0.020-inch overbore kit (PN 4C3Z-6R007-A) was used in the overhaul. These kits can be purchased at your local Ford dealer for $1,876.34 and come with every OE component needed to perform the rebuild: all gaskets, O-rings, seals, sensors, pistons, wristpins, connecting rod bearings, water thermostat, low-pressure oil pump, oil cooler, glow plugs, and more. Ford's 0.020-inch overbore kit (PN 4C3Z-6R007-A) was used in the overhaul. These kits can A full-on rebuild of a 6.0L isn't as complicated (or scary) as you might think. Recently, we stopped by Diesel Tech, the shop that built our last 7.3L Power Stroke ("Rebuilding it Right," May '10), to see an '04 version of the VT365 going together. Follow along, as we'll explain what aspects of the 6.0L you'll need to pay close attention to, how to reinforce the engine to ensure longevity, and which components should be replaced, rebuilt, or reused. *All our genuine Ford part costs came from Rodeo Ford in Goodyear, Arizona PARTS AND PRICE LIST: PART PART NUMBER PRICE 6.0L DIT diesel engine overhaul kit (0.020-inch overbore) 4C3Z-6R007-A $1,876.34 OE cylinder heads (2) 3C3Z-6049-DA $926.82 ($250 core, each) OE injectors (8) 4C3Z-9E527-BRM $203.01 ($180 core, each) OE high-pressure oil pump 4C3Z-9A543-AARM $467.50 ($150 core) OE VGT turbocharger 4C3Z-6K682-CCRM $929.50 ($250 core) Machine work and short-block assembly $800 to $1,200 (estimate) TOTAL 6.0L BUILD (labor not included) $5,211.06 - $5,611.06 (Core charges included) To address the concerns of the factory EGR cooler, an aftermarket EGR cooler from Neal Technologies was ordered for the build. The aftermarket cooler is street-legal, utilizes six heavy-duty internal exhaust tubes (instead of flat, thin exhaust channels), and is a direct-fit replacement part. On the right, you can see the stock EGR cooler's internals versus the hardware found inside the Neal Technologies cooler. To address the concerns of the factory EGR cooler, an aftermarket EGR cooler from Neal Tec The local machine shop, County Auto Machine, performed the machine work and assembled the short-block. From there, the technicians at Diesel Tech took over, installing the front cover, new low-pressure oil pump assembly (gerotor gear and oil pump housing) on the front of the crankshaft, and the low-pressure oil pump cover. In this photo, the water pump's pulley bracket is being installed. Shortly after production of the 6.0L began, Ford noticed the pulleys were cracking, so a bracket was implemented as standard equipment. The local machine shop, County Auto Machine, performed the machine work and assembled the After the front crank seal was installed using a Ford installer tool, a couple minor, but important sensors were installed-the water temperature sensor and oil temperature sensors supplied in Ford's overhaul kit. We can't stress the importance of replacing every sensor enough. Faulty or aged sensors can make an engine run too hot or cold, hydrolocking or toasting a brand-new engine. It's important to never cut corners in a complete diesel engine overhaul. After the front crank seal was installed using a Ford installer tool, a couple minor, but Also supplied in the overhaul kit were new camshaft and crankshaft sensors. The new crankshaft sensor is shown. According to Diesel Tech, it's very common for a worn, outside O-ring to leak (arrow, black O-ring) on the 6.0L engines. Also supplied in the overhaul kit were new camshaft and crankshaft sensors. The new cranks Prior to installing the rear cover, a small bead of silicone was placed where the bed plate and rear cover meet. The same went for the front of the engine where the bed plate and front cover meet. Prior to installing the rear cover, a small bead of silicone was placed where the bed plat Next, a new high-pressure oil pump (PN 4C3Z-9A543-AARM) was installed. When installing the mounting bolts, the guys at Diesel Tech were careful not to drop them down into the crankcase. The bolts were torqued to 18 ft-lb and then the high-pressure oil pump cover was installed. Next, a new high-pressure oil pump (PN 4C3Z-9A543-AARM) was installed. When installing the The injection pressure regulator valve (IPR) was installed using a six-point specialty socket, which surrounds the IPR but provides a gap that clears the electrical connector. The injection pressure regulator valve (IPR) was installed using a six-point specialty soc Next up, a set of ARP head studs (PN 250-4202) were threaded into the block. Then, the supplied, multi-layer head gaskets (five layers) were installed with the stamped numbers facing up. We should also note that because this was an '04 engine (and built before July 19, 2004), the cylinder head dowels' outside diameters measured 18 mm. After that, the new, pre-assembled driver-side cylinder head (PN 3C3Z-6049-DA) was set on the block. Unlike the 7.3L, the 6.0L features just four bolts per cylinder and 10 bolts per bank-which is why installing ARP head studs is so critical on these engines. Next up, a set of ARP head studs (PN 250-4202) were threaded into the block. Then, the sup Because of the IPR's location (and the fact that it is responsible for the high-pressure oil pump's outlet pressure), the factory aluminum foil heat wrap (arrow) is very important to retain. With the IPR's location so close to the turbo and exhaust plumbing, forgetting to reuse this could lead to premature failure and an engine that won't run. Because of the IPR's location (and the fact that it is responsible for the high-pressure o Then the driver-side rocker box was fitted with the supplied gasket and coated with a thin layer of assembly lube (Note: This is the bottom, which mates to the top of the cylinder head). The 6.0L Power Stroke's rocker boxes are aluminum, which some people mistake for actually being the cylinder heads from outside the vehicle and therefore believe the 6.0L has aluminum cylinder heads. Make no mistake about it-just like the 7.3L Power Stroke-the 6.0L uses cast-iron heads. Then the driver-side rocker box was fitted with the supplied gasket and coated with a thin It's important to note that, before the head studs get torqued, the rocker arms must first be fastened to 23 ft-lb. According to Jose Dega of Diesel Tech, tightening the head studs before the rocker arms can lead to a bent pushrod when the engine is started. Also worthy of mentioning, on '03 engines some of the clips that the rocker arms ride on were plastic and became notorious for breaking (this was not the case with our '04 engine). It's important to note that, before the head studs get torqued, the rocker arms must first Once all rocker arms were tightened, the head studs were torqued. ARP's Ultra-Torque assembly lubricant was used for this process. Ultra-Torque was designed to be a metal-free, consistent, and repeatable way to achieve the ideal torque preload on the first torque cycle. Once all rocker arms were tightened, the head studs were torqued. ARP's Ultra-Torque assem This is the recommended torque pattern that Dega followed. Starting from the center and working his way out, the first torque sequence called for 70 ft-lb, the second for 140 ft-lb, and the third for 210 ft-lb. This is the recommended torque pattern that Dega followed. Starting from the center and wo After the heads were secured to the block, eight new injectors (PN 4C3Z-9E527-BRM) were installed. For those rebuilding a 6.0L and retaining their injectors, all replacement O-rings are supplied in Ford's overhaul kit, including the O-rings on the injector harness connector plugs. After the heads were secured to the block, eight new injectors (PN 4C3Z-9E527-BRM) were in Next, the oil cooler was disassembled and then rebuilt using the supplied hardware in Ford's overhaul kit. Key items installed included a new engine oil temperature sensor, oil sending unit, oil relief valve, gasket, and all O-rings and seals. Then the rebuilt oil cooler was placed in the lifter valley. Next, the oil cooler was disassembled and then rebuilt using the supplied hardware in Ford The finishing touches on the engine included the install of new intake gaskets, the intake manifold, the Neal Technologies EGR cooler, and all electronics. A new, variable-geometry turbo (PN 4C3Z-6K682-CCRM) was also bolted onto what became an affordably rebuilt, near-bulletproof 6.0L Power Stroke. The finishing touches on the engine included the install of new intake gaskets, the intake SOURCES Automotive Racing Products 1863 Eastman Avenue Ventura CA 93003 800-826-3045 http://www.arp-bolts.com Ford Parts Glendora CA http://www.fordparts.com Diesel Tech 1685 S State St. San Jacinto CA 92583 951-766-5777 http://www.dieseltech1.com/ Rodeo Ford 1788 Saamis Drive NW Medicine Hat, Alberta Medicine Hat, Alberta Canada T1C1W7 1-877-910-7788 www.rodeoford.com County Auto Machine San Bernadino CA 951-487-0917 Neal Technologies 134 East Broadway Road Mesa AZ 85210 N/A http://www.bulletproofdiesel.com/ By Mike McGlothlin Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!