6.0L Power Stroke Changes And Revisions

6.0L Power Stroke Engine Changes by Model Year

Model Year 2004 6.0L Power Stroke Changes

The following changes affect engines manufactured after September 29, 2003.
- Revised EGR cooler design. 2004-2007 EGR cooler is longer and a square design replaces the circular cooler found on 2003 engines.
- New "wavy" high pressure oil rail and delivery system. Increases volume of high pressure oil system.
- Improved casting of the upper oil pan increases strength.
- Upgraded camshaft design featuring different lobe seperation angle, lobe lift, and duration characteristics. Improves combustion efficiency, reducing emissions. 2004+ camshaft should not be used in 2003 model engines.
- Modified piston bowl design for improved emissions reduction. Shorter glow plugs required. 04+ glow plugs not compatible in 2003 engines; piston contact and destruction can result.
- Larger water pump impeller to increase coolant flow and combat high temperatures resulting from the EGR cooler. (Impeller increased from 90 mm to 100 mm).
- FICM recieves larger vibration dampers to eliminate failure caused by engine harmonics.
- New turbocharger turbine wheel with 3 additional fins to reduce noise caused by the turbo.
-Injector plungers coated with DTC (diamond like carbone) to increase injector life.
- ICP sensor relocated to valve cover. Sensor can be removed/replaced without removing valve cover.

2005 Model Year 6.0L Power Stroke Changes

- New EGR valve with shaft seal reduces leaking of exhaust gases. Not interchangeable with 2003/2004 model year engines. Diverter plates incorporated into the intake manifold to distribute exhaust gases equally between banks.
- EGR throttle plate removed. Scoop added in exhaust up pipe to direct exhaust flow into the EGR system. Throttle plate deemed redundant.
- Updated turbocharger shaft bearings for improved turbo longevity and reduced shaft play.
- New HPOP (high pressure oil pump) design. Flow is comparable to previous HPOP. Improved oil pressure and pump response at low engine speeds. Improved pump longevity.
- New front engine cover with different coolant passage locations. Designed to make room for new power steering pump design. Not interchangeable with 2003/2004 model 6.0L Power Strokes.