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Ford Power Stroke engine
Manufacturer	Navistar International
Also called:	International Truck and Engine Corporation
Production:	1983–

Introduced in 1994, as a Mid Year Model Change (1994.5), turbodiesel truck engines used in Ford F-Series trucks, the Ford Econoline van, the Ford LCF commercial truck, and the Ford Excursion SUV. The Power Stroke is manufactured by Navistar International Corporation (International Truck and Engine Corporation) and is based on a design for a gasoline-powered V8 from International Harvester. Four different engines have been made based on this original design, the 420 cu in (6.9 L), 444 cu in (7.3 L), 365 cu in (6 L), and 388 cu in (6.4 L); the last three have used the Power Stroke name. These engines are built in Indianapolis, Indiana and Huntsville, Alabama.

These engines primarily compete in the United States full-size pickup truck market with the Duramax V8 from General Motors/DMAX and the B series straight 6 from Dodge/Cummins.

Contents 1 6.9 1.1 Specifications 2 7.3 3 6.0 4 6.4 5 Applications 6 See also 7 References 8 External links

The roots for the 6.9L go back to 1978, when the International Harvester Corporation began developing the 420 ci. 6.9L Diesel. The 420 cu in (6.9 L) International's Engine was used by Ford from 1983 through 1987, though it did not use the Power Stroke name. Unlike the larger engines, it used indirect injection.

• Engine Description: IHI 6.9L Diesel
• Displacement: 6.9L / 420 ci.
• Bore x Stroke: 4.00 x 4.18 (in.)
• Block / Head: Cast iron / Cast iron
• Aspiration: Natural
• Valvetrain: OHV 2-V
• Compression: 20.7:1
• Injection: Indirect, Stanadyne DB2
• Horsepower / Torque (at start): 170 hp (127 kW) / 310 ft·lbf (420 N·m).

For 1988, Ford replaced the old 420 cu in (6.9 L) with a larger 445 cu in (7.3 L) version. This was upgraded in 1993 with an optional turbocharger and again in mid 1994 when electronics and direct injection were added; the new configuration was named the Power Stroke and lasted through the end of 2003. This model produced Template:210hp and 525 ft·lbf (712 N·m) of torque in its last production year. The 7.3 is widely considered the most durable of the diesel motors in the industry.

Unable to meet stricter emissions regulations, the 7.3L (445 cu in) Power Stroke was replaced by the 6.0 L (366.1 cu in) during the 2003 year model. This version lasted through 2006 (2007 model year). Many 6.0 L Power Stroke engines proved unreliable,^[1] may have cost Ford hundreds of millions of dollars in warranty repairs and leading to a recall and repurchase of at least 500 trucks. The major problem with the Navistar diesel engines are due to damage resulting from defective fuel injectors, which suffer from side loading, which then causes raw fuel to flood and enter the engine's oil crankcase or hydro-lock the engine. The previous occurrence is so disastrous that a total engine replacement in some cases, has been required. There were also minor problems resulting from the unreliable factory variable-vane turbocharger, head gasket problems, EGR valve carbon deposit clogging/sticking, defective Exhaust Pressure (EP) sensor/connector, extensive PCM recalibrations, fuel injector harness chafing/crushing, general engine stalling/bucking, and inability to conform to the new Federal diesel emissions standards of January 1, 2007. There were many running changes to the engine and in the 2006 year model the 6.0 had the least amount of warranty claims across the board for Ford motor company when compared to all of Ford's gas and diesel engines they used.

The engine had an 3.74 in (95 mm) bore and 4.13 in (104.9 mm) stroke for a displacement of 365 cu in (6 L) or 5954 CC. It utilized a turbocharger and intercooler, producing 325 hp (242 kW) and 570 ft·lbf (773 N·m) with an 18:1 compression ratio, redlining at 4500 rpm.

This engine is still being utilized in the E-series until the end of the 2009 calendar year. The engine is the same configuration as the 2007 YM with a diesel particulate filter added to the exhaust system.

To meet even stricter emissions regulations for 2007, the 6.0L engine was replaced by the 6.4 L (390.6 cu in) Power Stroke. Ford introduced its redesigned 2008 Super Duty lineup in early 2007 equipped with the new 6.4 liter Power Stroke.

The new engine has a 3.86 in (98 mm) bore and 4.13 in (104.9 mm) stroke, resulting in a total calculated displacement of 387 cu in (6.3 L) or 6.3 L (6333 cc). This new engine bumped the power up to 350 hp (261 kW) and torque to 650 ft·lbf (881 N·m) at the crank. Horsepower and Torque is achieved at 3,000 rpm and 2,000 rpm respectively. It also features a sequential turbo system, with a smaller fixed vane turbo providing a constant boost to a bigger variable geometry turbo resulting in almost no turbo spooling when taking off from a stop. The new turbo system also provides better power response while already in motion acting much like a gasoline engine in throttle response. The engine also has a Diesel Particulate Filter. The engine computer is also programmed to periodically inject extra fuel (regeneration in F-Series) to burn off accumulated soot into ash.

Many more changes have taken place with the 6.4 liter Power Stroke and other on-highway diesel engines built after January 1, 2007. The two major changes are the fuel and oil. The fuel required is Ultra-low sulfur diesel (15 PPM sulfur). The fuel is backwards compatible with all earlier diesel engines. The oil will be classified as CJ-4 vs. the previous CI-4 and CI-4 plus. CJ-4 oil must be used in all diesel engines requiring the ULSD and is backwards compatible to approx 12 years for all diesels.

The 6.4 has had one recall due to the potential for diesel fuel or oil in the DPF causing very high EGTs (exhaust gas temperatures). The recall reflashes the engine computer to derate the fuel in order for the engine to reduce the DPF temperature if a high exhaust temperatures is found to be above Ford's specifications.

F Series and Excursion Applications

• • 1994–2003 7.3 L
  • 2003–2007 6.0 L
  • 2008– 6.4 L

E Series Applications

• • 1988-1994 7.3lt. IdI
  • 1994–2003 7.3 L
  • 2004–2007 6.0 L

LCF (Low Cab Forward) Application

• • 2005–current 4.5 L

• Ford engines
• Ford Triton engine

1. ^ Launch in Limbo. AutoWeek. Retrieved on March 5, 2007.

• Powerstroke Diesel home page