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Attachment VI - Certain 2004 & 2005 MY 6.0L





OVERVIEW

This program involves replacing the exhaust pressure (EP) sensor and recalibrating the powertrain control module (PCM), transmission control module (1CM) and the fuel injection control module (FICM) with the latest software.

EP SENSOR REPLACEMENT

F-SUPER DUTY AND EXCURSION MODELS - VEHICLES BUILT FROM JUNE 1, 2004 THROUGH NOVEMBER 2, 2004





NOTE:
On vehicles built before November 3, 2004, the EP sensor is located on a bracket directly in front of the left cylinder head between the front lifting bracket and the charge air cooler (CAC) tube. See Figure 1.

1. Remove the air filter cartridge and the outlet tube assembly.

2. Remove the CAC outlet tube (driver side of vehicle).

3. Disconnect the EP sensor.

4. Remove the EP sensor.

5. Install the new EP sensor and tighten to 10 Nm (89 lb-in).





6. Connect the EP harness connector.

7. Install the CAC outlet tube. Tighten the clamps to 12 Nm (9 lb-ft).

8. Install the air filter and outlet tube assembly. Tighten the clamps to 4 Nm (35 lb-in).

9. Proceed to Module Recalibration in this Attachment VI.

F-SUPER DUTY AND EXCURSION MODELS - VEHICLES BUILT FROM NOVEMBER 3, 2004 THROUGH JANUARY 18, 2005





NOTE:
On vehicles built on or after November 3, 2004, the EP sensor has been moved rearward and is located near the FICM on the left valve cover. See Figure 2.

1. Remove the air filter cartridge, the outlet tube and the clean air tube.

2. Disconnect and clamp off the small hose from the passenger side of the degas bottle and plug the hole in the bottle.

3. Remove the two (2) bolts and position the degas bottle aside.

4. Disconnect the EP sensor. See Figure 2.

5. While holding the tube nut with a wrench, remove the EP sensor.

6. Install the new EP sensor and tighten to 10 Nm (89 lb-in).

7. Connect the EP sensor.

8. Install the air filter cartridge, the outlet tube and the clean air tube. Tighten clamps to 4 Nm (35 lb-in).

9. Reposition the degas bottle and install the two (2) retaining bolts. Tighten bolts to 10 Nm (89 lb-in).

10. Remove the plug and the clamp, then reconnect the hose to the degas bottle.

11. Proceed to Module Recalibration in this Attachment VI.

E-SERIES - VEHICLES BUILT FROM JUNE 1, 2004 THROUGH MARCH 3, 2005

1. Remove the engine cover from inside the passenger compartment.





2. Disconnect the EP sensor. See Figure 3.

3. While holding the tube nut, remove the EP sensor.

4. Install the new EP sensor and tighten to 10 Nm (89 lb-in).

5. Connect the EP harness connector.

6. Install the engine cover.

7. Proceed to Module Recalibration in this Attachment VI.

MODULE RECALIBRATION

NOTE:
This recalibration, using WDS software Version B40.7 or higher, or B41.1 or higher, will update the PCM, TCM and FICM. This new calibration is not included in the B41 CD. Calibration files may also be obtained at the website.

1. Connect a battery charger to the vehicle.

2. Using Worldwide Diagnostic System (WDS), recalibrate the modules to the latest level calibration.

3. VERIFY THE WDS IS LOADED WITH SOFTWARE VERSION B40.7 OR HIGHER, ORB41.1 OR HIGHER.

4. Select Module Configuration Programming (MCP) and follow the WDS display instructions.

^ If unable to recalibrate the modules:

- module replacement will not be covered under this program.

- prior to disconnecting the WDS from the vehicle and closing the session, call the Special Service Support Center.

5. Perform a self-test to verify there are no further concerns.

6. Proceed to Road Test Procedure in this Attachment VI.

ROAD TEST PROCEDURE

Check OASIS to verify there are no other Field Service Actions applicable to this vehicle prior to performing the Road Test Procedure.

Test drive the vehicle to make sure no drivability concerns exist prior to returning the vehicle to the owner.

NOTE:
To address any customer concerns for vehicles that are out of warranty and exhibit engine performance issues after the road test, please follow the guidelines in the Warranty and Policy Manual.

AUTHORIZED MODIFICATIONS LABEL INSTALLATION





1. Obtain and prepare the Authorized Modifications Label. Describe the modification performed, and enter your P&A Code, date of repair and the program type and program number. See Figure 4.

PROOF OF CORRECTION CERTIFICATE





1. Provide the owners of vehicles registered in California and Massachusetts with a completed "Vehicle Emissions Recall - Proof of Correction" certificate. See Figure 5.
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