• ENGINE—7.3L DIESEL—1999 ENGINE CONTENT Article No. REVISIONS ...

ENGINE—7.3L DIESEL—1999 ENGINE CONTENT Article No.
REVISIONS 03-21-33
FORD: 1999 E SERIES, SUPER DUTY F SERIES
Article 99-7-7 is being republished in its entirely as High Pressure Oil System
part of a consolidated 7.3L diagnostic aid booklet. • New high pressure oil gallery plug for service that
places the sealing O-rings deeper into the gallery.
ISSUE The new plug is identified with a circular groove
Significant changes have been made to the 7.3L cut into the face of the plug. The new plug went
DIT engine effective with the release of the 1999.5 into production prior to the 1999.5 MY on engine
Model Year (MY) (December 1998). The major S/N 751869 (Figure 2).
areas addressed are the air intake system,
turbocharger, injectors, and air cleaner. • New high pressure oil pump with higher flow rate
(7.2cc versus 6.8cc 1999 model year and prior).
ACTION Turbocharger
Refer to the following text and Part Application
Chart for the correct part description and correct • New higher efficiency turbocharger. Turbo
part usage when servicing subject engines. compressor outlet diameter and compressor size
increased to improve air flow. Taller pedestal
SERVICE PROCEDURE provides better clearance (Figure 3).
• New exhaust inlet adapter allows access to the
HIGHLIGHTS
fuel pressure test port at the rear of the head.
Fuel System • New exhaust up-pipes with inlet adapter.
• Tungsten carbide-coated injector plunger and • Econoline uses the new larger, taller turbo without
barrel. Lessens the chance of injector damage by the wastegate or charge air cooling provisions.
low lubricity fuel and water.
Charge Air Cooler
• New fuel pressure regulator (1999 MY). Fuel
pressure on all Powerstroke engines built since • New Charge Air Cooler (CAC) crossover is
1/18/1998 or engine Serial Number (S/N) 551496 incorporated with the new turbo (Figure 4).
should be 352 ±31 kPa (51 ±4.5 psi) at idle. • A Powertrain Control Module (PCM)-controlled
intake air heater is installed in the air inlet (after
NOTE the CAC) to the engine side of the CAC
THE NEW INJECTORS AND/OR PUMP CANNOT crossover. The Econoline heater is in the Y-pipe
BE USED IN PRE-1999.5 MODEL YEAR ENGINES downstream of the turbo. The new intake heater
AND THE PRE-1999.5 MODEL YEAR PUMP AND is used to heat the air before it reaches the
INJECTOR CANNOT BE UTILIZED IN 1999.5 combustion chamber in the engine during cold
MODEL YEAR ENGINES. startup to reduce cold smoke. Current to the
• A dual element fuel filter was incorporated during intake heater is switched on/off by a
the 1999 model year to filter the fuel that is PCM-controlled relay, similar to the glowplug relay
returned to the tank via the fuel filter regulator. (Figure 5).
The Ford Replacement Part number for this filter • Both E- and F-Series use a new intake cover with
is now F81Z-9N184-AA (Figure 1). 76mm (3″) inlets into the heads for better flow to
the combustion chambers (Figure 6).
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do
the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper
vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a
Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle.
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Copyright © 2003 Ford Motor Company 099-2003-0023r2 099-2003-0023r2 PAGE 1
 Article No. 03-21-33 Cont’d.
PART APPLICATION
Previous Part
Part Name 1999.5 Part Number Number
Air Heater Relay F81Z-6G015-AA
Air Heater F81Z-9N424-AA
Air Heater Insulator 1831643-C1 (N*)
Air Heater Sealing Washer 1827886-C1 (N*)
Air Heater Wave Washer 1831644-C1 (N*)
Air Cleaner (F-Series) XC3Z-9600-AA F81A-9600-AD
Charge Air Cooler (CAC) Duct-to-Intake Manifold F81Z-6K889-CA F81A-6K889-AA
Cylinder Head Covers (Econoline/F-Series) F81Z-9E434-CA
Engine Wiring Harness - Federal (F-Series) F81Z-12B637-EA
Engine Wiring Harness - California (F-Series) F81Z-12B637-DA
Engine Wiring Harness - Federal (Econoline) XC2Z-12B637-EA
Engine Wiring Harness - California (Econoline) XC2Z-12B637-FA
Exhaust Muffler Extension Pipe (156.2″ W.B.) XC3Z-5A212-BA
Wide Frame - Exhaust Muffler Extension Pipe (F-Series 172.4″ W.B.) XC3Z-5A212-CA
Wide Frame - Exhaust Muffler Extension Pipe (F-Series 158″ W.B.) XC3Z-5A212-DA
Wide Frame - Exhaust Muffler Extension Pipe (F-Series 141.8″ W.B.) XC3Z-5A212-EA
Wide Frame - Exhaust Muffler Extension Pipe (F-Series 164.8″ W.B.) XC3Z-5A212-FA
Narrow Frame - Exhaust Muffler Extension Pipe (F-Series 176.2″ W.B.) XC3Z-5A212-GA
Narrow Frame - Exhaust Muffler Extension Pipe (F-Series 161.8″ W.B.) XC3Z-5A212-HA
Narrow Frame - Exhaust Muffler Extension Pipe (F-Series 200.8″ W.B.) XC3Z-5A212-JA
Narrow Frame - Fuel Filter Element Package F81Z-9N184-AA F81Z-9N184-AA
Fuel Supply And Return Lines F81Z-9J338-NA F81A-9J338-NA
High Pressure Oil Pump F81Z-9A543-CRM F81A-9A543-BA
Injector (Tungsten Carbide) F81Z-9E527-BRM F81A-9E527-ARM
Power Feed Cable (Econoline) XC2Z-12B568-BA
Regulating Valve Package F81Z-9B249-BB F81Z-9B249-BA
Turbocharger Exhaust Inlet Adapter F8TZ-6K854-AA
Turbo Pedestal With Exhaust Back Pressure (EBP) F81Z-6N639-CARM F81A-6N639-AA
Turbo Pedestal Without EBP (F-Series) F81Z-6N639-DARM F81A-6N639-BA
Turbocharger With EBP (F-Series) F81Z-6K682-BARM F81A-6K682-AA
Turbocharger Without EBP (F-Series) F81Z-6K682-CARM F81A-6K682-AARM
Turbocharger Without EBP (Econoline) XC2Z-6K682-AARM F8UZ-6K682-AARM
Wastegate Actuator Kit With EBP (F-Series) F81Z-6F089-AA
Water Drain Cable (Econoline) XC2Z-9J312-AA F7UA-9J312-AA
(N*) Navistar SUPERSEDES: 99-7-7
WARRANTY STATUS: INFORMATION ONLY
OTHER APPLICABLE ARTICLES: NONE
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Figure 2 - Article 03-21-33
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 Article No. 03-21-33 Cont’d.
Figure 3 - Article 03-21-33
Figure 4 - Article 03-21-33
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Figure 5 - Article 03-21-33
Figure 6 - Article 03-21-33
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