Engine Replacement Questions - Ford Powerstroke Diesel Forum
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post #1 of 6 Old 06-12-2014, 06:26 PM Thread Starter
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Engine Replacement Questions

I have an '04 6.0L with 180K miles and what looks to be a major internal issue that may warrant either a major costly repair or engine replacement. I have access to a decent 03 6.0. I know the replacement engine will fit in my body and I assume the tranny will bolt up, but what else will need to be done? Will my wiring harness/FICM work? What if I get the 03 FICM/wiring harness with the engine, will this be a better fix?
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post #2 of 6 Old 06-12-2014, 08:36 PM
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Your harness may work, but there are some changes to positions of plugs and sensors (ICP ., etc). The engine doesn't operate differently, just that the FICM and ECU should be matched. With the CAM being a bit different, it may need the 03 ECU as well.

Frank
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post #3 of 6 Old 06-13-2014, 01:24 PM Thread Starter
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I'm not good with acronyms. I know the FICM is the Fuel Injection Control Module. Is the ECU the Electronic Control Module? Let's say I put the FICM, ECU and wiring harness from the new engine into my body. Will this affect the transmission or any gauges in any way?
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post #4 of 6 Old 07-01-2014, 02:51 PM Thread Starter
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Update... the replacement of the late 04 with the early 03 was a lot of work, but most of the kinks are worked out. I ended up taking almost every external part from the 04 and putting it on the 03. FICM, Oil Cooler/Filter housing, intake mainfold, turbo, turbo stand, tubo drail pipe, fan, fan shroud, and several other odds and ends. In hindsight, it would have been much faster and easier to use the 03 parts, but I saw the old style intake being a b&$ch if I ever had to pull the turbo (which I did, almost immediately after getting it put back together). The hardest part of the entire swap was getting the tranny mounted back up to the engine.

I did use the 03 wiring harness because of the position of sensors, ICP, etc. So far, it's running great after I tackled an oil and coolant leak issue that developed because of my oversight to begin with.
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post #5 of 6 Old 07-01-2014, 05:31 PM
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Updates are a lot of work to work around! Yes the transmission can be nice if everything is perfectly lined up, otherwise... well let's just say you got your money's worth of experience.

Frank
2007 F-250 Lariat Crew. MBM 190/50s,
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Want to modify your injectors DIY - http://www.powerstroke.org/forum/6-0...ger-flows.html

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post #6 of 6 Old 07-01-2014, 09:01 PM
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Sounds like alot of work. The 03 intake doesnt really affect turbo removal on a 03 turbo not sure about an 04.

Do you think it ended up being worth it vise getting a long block to throw in there?
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