Ford Powerstroke 6.0L Turbocharger Carbon Deposit Diagnostics


Reference Number(s): 09-16-5, Date of Issue:  August 24, 2009

FORD: 2003-2005 Excursion; 2003-2007 F-Super Duty; 2004-2009 E-Series; 2004-2007 F-650, F-750

Superceded Bulletin(s): 09-12-2, Date of Issue:  June 29, 2009, 07-21-4, Date of Issue:  October 29, 2007

NOTE: This article supersedes TSB’S 09-12-2 and 07-21-4 to direct repairs to the Workshop Manual (WSM) Turbocharger Reconditioning procedure added to the online WSM and updates to the pinpoint test (PPT) in the Powertrain Controls/Emission Diagnostic (PC/ED) manual.



Some 2003-2007 F-Super Duty, 2004-2007 F-650/750, 2003-2005 Excursion and 2004-2009 Econoline vehicles equipped with a 6.0L diesel engine may exhibit any one, or a combination of the following concerns: lack of power, white/black smoke or a surge.

On 2003-2007 F-Super Duty, 2003-2005 Excursion, and 2004-2009 Econoline these concerns may or may not be accompanied by any one, or a combination, of the following diagnostic trouble codes (DTCs): P0238, P0299, P0404, P0478, P2262 and/or P2263. These concerns and/or DTCs could be a result of coking deposits inside the turbocharger.

On 2004-2007 F-Super Duty 650-750, these concerns may or may not be accompanied with the following DTCs: 261, 342, 343, 353, 354 and/or 361. These concerns and/or DTCs could be a result of coking deposits inside the turbocharger.


Follow the Service Procedure steps to correct the condition.


Coking deposits inside the turbocharger turbine housing can impede vane response causing high or low instances of exhaust pressure. Unexpected exhaust pressure results can cause over-boost, under-boost, insufficient or excessive exhaust gas recirculation, or unexpected EGR valve position, resulting in these symptoms.

For F-Super Duty, Excursion, E-Series vehicles built on or before 9/29/2003, follow PPT KA in the PC/ED manual diagnostics. If the PPT in the PC/ED manual diagnostics leads to turbocharger replacement, use the Turbocharger Inspection Procedure first to check for internal turbocharger oil leaks. Then, determine if the turbocharger can be repaired with a center housing rotating assembly (CHRA) replacement or if it can be cleaned instead of replacing the entire turbocharger following the turbocharger reconditioning service procedure.

For F-Super Duty, Excursion, and E-Series vehicles built on or after 9/30/2003, perform the Powertrain Air Management Turbo Boost test and VVT test with IDS. Use of the VPS tool 418-626 along with IDS/VMM is required. Tool 418-626 was shipped in kit TKIT-2007VP-F and TKIT-2007TV-F. Dealers should have received one or the other of these two kits.

Refer to the updated online WSM, Section 303-04D: for diagnosis, testing and reconditioning of the turbocharger assembly.

For F-Super Duty 650-750 vehicles, refer to the updated online WSM, Section 303-04B: for diagnosis, testing and reconditioning of the turbocharger assembly.

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Part Number Part Name
6C3Z-9T515-A Oil Drain Tube
3C3Z-9G489-AARM Center Housing – 2003 F-Super Duty/Excursion
3C3Z-9G489-BARM Center Housing – Bolted w/o Clamp Plate, 2003 F-Super Duty/Excursion
4C3Z-9G489-AARM Center Housing – 2004-2005 F-Super Duty (Built before 11/4/2004), E-Series, And Excursion (Built before 1/10/2005)
5C3Z-9G489-AARM Center Housing – 2005 Excursion (Built after 1/10/2005), 2005-2007 F-Super Duty (Built after 11/4/2004) And 2005-2009 E-Series
XL-2 Motorcraft® High Temperature Nickel Anti-Seize Lubricant
PM-2 Motorcraft® Carburetor Tune-Up Cleaner
W302676 V-Band Clamp
W302677 Locknut
3C3Z-6C885-A Unison Ring


WARRANTY STATUS:  Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage.

IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

Operation Description Time
MT091605 Use SLTS Operations If Available; Claim Additional Diagnosis Or Labor Performed As Actual Time Actual Time

Basic Part No. Condition Code
6K682 42
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