2003-2007 Ford F-250 and F-350 Superduty trucks contain one of the most well-known diesel engines in modern day diesel trucks, the 6.0L Powerstroke V8 engine. Upon being released, consumers had high hopes for this latest iteration of the Superduty. This was especially true considering this engine was replacing the legendary 7.3L Powerstroke V8 Diesel engine which had set the bar extremely high for Ford trucks.

Despite the reliability of its predecessor, the 6.0L Powerstroke became well-known for entirely different reasons. In this post, our 2003-2007 Ford F-250/F-350 Superduty 6.0L Powerstroke Guide, we’re going to dive in deep about the good, the bad, and the ugly of these trucks.

We’ll cover Ford Superduty 6.0L Powerstroke performance, specs, history, and tow ratings. We’ll also list common Ford Superduty 6.0L Powerstroke problems, and what can be done to fix them. Let’s get started.

6.0L Powerstroke V-8 Diesel Engine

The 6.0L Powerstroke engine was built by International Navistar, similar to the 7.3L Powerstroke. Planning and design for this new engine began in the late 90s as Ford was aware of upcoming and stringent emissions guidelines that were being implemented. In addition to stricter emissions, the 7.3L Powerstroke was becoming underwhelming from a performance aspect. Both the 5.9L Cummins and the LB7 Duramax engines were catching up, or even surpassing the 7.3L Powerstroke in capabilities.

In 2003, Ford introduced the 6.0L Powerstroke engine in Ford F-250 and F-350 Superduty trucks. It was in production until the 2007 model year, after which it was replaced by the 6.4L Powerstroke V8 Diesel Engine.

Engine Design

The 6.0L Powerstroke is a direct-injection, 32-Valve, 8-cylinder Diesel engine that boasts significantly improved power, fuel economy, and NVH (noise, vibration, harshness) over the previous 7.3L Powerstroke V8 Diesel engine. It also contains a lower displacement, and is more compact than the engine it replaced. This engine has an Overhead valve design, with a single, block-mounted camshaft, featuring hydraulic valve-lash adjustment. This results in lesser friction resulting in greater valvetrain durability, improved longevity, quieter operation, and better performance.

Utilizing a cast-iron cylinder block for superior strength, the 6.0L Powerstroke features a sturdy foundation. To help accomplish its compact design, the geartrain for the crankshaft, camshaft and the HPOP (high-pressure oil pump) were moved to the engine’s rear. Further bottom-end strength was accomplished by the use of a crankcase bed plate.

Similar to the 7.3L Powerstroke, powdered-metal connecting rods are used, with great success. These connecting rods have been found to be capable of supporting massive performance improvements. Cast Aluminum Pistons are also used.

6.0L Powerstroke engines contains cast iron cylinder heads, which are significantly higher flow than the outgoing 7.3L Powerstroke. Four valves are used per cylinder, for a total of 32 valves. Aluminum rocker boxes mount to the top of each cylinder head. The cylinder heads themselves are mounted to the block with four 14mm TTY head bolts used per cylinder. These Torque-to-yield bolts are small compared to those used in other diesel applications, and also fewer in number. They’re known to stretch when the engine is put under higher loads due to heavy towing or engine mods like 6.0L Powerstroke Tuning. Once they’ve stretched, they will no longer apply the same clamping force, ultimately resulting in a blown head gasket.

Engine Highlights

The 6.0L Powerstroke V8 Diesel Engine brought some innovations never before seen on a Ford Diesel truck. These engines use EGR, or exhaust gas recirculation, as a means of significantly reducing emissions output and meeting federally mandated emissions requirements. Electronic Variable Response Turbocharging is introduced through the use of a variable geometry turbocharger. An updated fuel design also was introduced, helping to reduce emissions output and increase performance capabilities.

Exhaust Gas Recirculation (EGR)

Exhaust gas recirculation is the process in which cooled exhaust gases get re-circulated back into the combustion chamber. This lowers the burner temperature at which combustion occurs, ultimately leading to reduces NOx emissions.

While the EGR did help reduce emissions enough for Ford to meet emissions requirements, they essentially opened a can of worms. EGR failure is one of the most common 6.0l Powerstroke Problems. Exhaust gas recirculation is extremely hard on engine coolant and introduces excess carbon and soot into multiple components including the EGR valve, EGR Cooler, intake manifold, and more.

Variable Geometry Turbocharger & Electronic Variable Response Turbocharging

A revolutionary turbocharging system was introduced the 2003 Ford Superduty with the introduction of the 6.0L Powerstroke engine. A variable Geometry, Garrett GT3782VA turbocharger is used in conjunction with an air-to-air intercooler. This turbocharger optimizes boost and performance over a wide range of driving scenarios.

This variable geometry turbocharger, also called Electronic Variable Response Turbocharging, or EVRT, uses a set of electronically controlled, hydraulically actuated vanes. These vanes automatically adjust, changing airflow within the turbo. This design results in optimum performance in the entire operating range. At lower speeds, it functions as a smaller turbocharger, resulting in quicker spooling and faster response. At higher operating ranges, it functions as a larger turbo for maximum power output.

While extremely innovative, the VGT actually is a common 6.0L Powerstroke problem as well. The VGT can experience buildup that causes the vanes to get stuck. A thorough cleaning or total replacement can fix the problem. There are plenty of 6.0L Powerstroke aftermarket turbocharger upgrades available on the aftermarket.

Hydraulic Rail Fuel Injection

Ford’s Superduty with the 6.0L Powerstroke V8 Diesel engine gained an updated fuel injection system. In this system, commonly referred to an a HEUI system, high-pressure engine oil helps compress diesel fuel. The Fuel injectors are controlled by a high-pressure hydraulic rail system that’s capable of delivering injection pressures of up to 26,000 psi. The result is a more powerful, efficient, and cleaner combustion.

Key Components of the Hydraulic Rail Fuel Injection System include:

• Powertrain Control Module (PCM)
• Injector Driver Module (IDM)
• High-pressure Oil Pump (HPOP)
• Injection Pressure Regulator (IPR)
• Siemens Injectors

This system, while it did help significantly boost the 6.0L Powerstroke’s performance and helped reduce emissions, is actually a common failure point of these engines too.

Ford 6.0L Powerstroke V8 Diesel Engine Specs

Engine:	6.0L Powerstroke V-8 Diesel Engine
Engine Design:	Turbocharged V-8 Diesel
Engine Weight	Approximately 966 lbs
Transmissions:	5-Speed 5R110W Torqshift Automatic ZF6 6-Speed Manual
Displacement:	6.0 Liters or 365 Cubic Inches
Bore:	3.74 inches or 95 mm
Stroke:	4.134 inches or 105 mm
Block Material:	Cast Iron Block
Connecting Rods:	Powdered-metal
Pistons	Cast Aluminum
Cylinder Head Material:	Cast Iron Cylinder Heads 4 valves per cylinder head 4 14mm head bolts per cylinder
Intake Manifold:	Aluminum
Compression Ratio:	18.0:1
Firing Order:	1-2-7-3-4-5-6-8
Turbocharger/Air:	Garrett VGT GT3782 TurboCharger, Air-to-Air Intercooler
Fuel Injection:	HEUI, Hydraulic Actuated electronic unit injectors
Valvetrain:	OHV (Overhead Valve) Single Cam, 32 Valve (4 valves per cylinder)
Engine Oil Capacity:	15 Quarts with filter
Emissions Devices	EGR – Exhaust Gas Recirculation
Cooling System Capacity:	27.5 Quarts or 8.75 Gallons.
Fuel:	Diesel
Fuel Tank Size:	29 Gallon or 38 Gallon Options
Horsepower:	325 horsepower @ 3,300 rpms
Torque:	2003-2004: 560 lb.-ft @ 2,000 rpm 2005-2007: 570 lb.-ft @ 2,000 rpm

Ford Superduty 6.0L Powerstroke Performance

There was a lot to be excited about with the introduction of the 6.0L Powerstroke V8 Diesel to the Ford F-250 and F-350 Superduty. For starters, the 6.0L Powerstroke engine gave the Ford Superduty a big increase in performance. 2003 Ford Superduty trucks with the 6.0L Powerstroke engine produce 325 horsepower and 560 lb.-ft of torque. When compared to the max figures of 275 horsepower and 525 lb.-ft of torque produced by the 7.3L Powerstroke, these were much needed performance gains. The 5.9L Cummins and the 6.6L LB7 Duramax were already posting figures that were vastly superior to those of the 7.3L Powerstroke as well, solidifying the need for an updated engine to stay competitive.

In addition to benefitting from the addition of a new, higher performance diesel engine, a new 5-speed TorqShift automatic transmission was also introduced. After being around for an extended period of time, this 5-speed automatic has proven itself to be quite reliable and capable of withstanding moderate performance upgrades.

These additions made the trucks drive smoother, made them more capable, and added to the max towing capacities of these trucks. It also aided these trucks in meeting federally mandated emission standards. Overall, the 6.0L Powerstroke allowed Ford’s Superduty to better compete with rivals thanks to the large jump in performance.

2003-2007 Ford Superduty Performance Comparison

The introduction of the 6.0L Powerstroke V8 Diesel engine made Ford more competitive against rival automakers GM and Dodge. How does it hold up against the other powertrains available within the Superduty lineup though? Check out how the 6.0L Powerstroke holds up against it’s fellow Ford Superduty powertrains in this chart down below.

Spec Type	Transmission	Years	Horsepower	Torque
5.4L V8 Triton	Automatic Manual	2003-2004 2005-2007	260 horsepower 300 horsepower	350 lb.-ft 365 lb.-ft
6.8L V10 Triton	All Options	2003-2004 2005-2007	310 horsepower 362 horsepower	425 lb.-ft 457 lb.-ft
6.0L Powerstroke V8 Diesel	Automatic	2003-2004 2005-2007	325 horsepower	560 lb.-ft 570 lb.-ft
7.3L Powerstroke V8 Diesel	Manual Automatic	2003 Only	275 horsepower 250 horsepower	520 lb.-ft 525 lb.-ft

Ford Superduty 6.0L Powerstroke Towing Capacity

The following Charts display max towing capacity for 2003-2007 Ford Superduty Trucks with the 6.0L Powerstroke V8 Diesel engine. Actual tow capacity for your vehicle can vary. Check your owner’s manual or Ford resources for exact towing capacity.

Manual Transmission F-250/F-350 Superduty SRW Towing Specs

Manual Transmission Spec Types	Year	F-250/F350 SRW Regular Cab	F-250/F-350 SRW SuperCab	F-250/F-350 SRW Crew Cab
Max Conventional Tow Capacity 4×2	2003 2004 2005 2006 2007	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs
Max Conventional Tow Capacity 4×4	2003 2004 2005 2006 2007	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×2	2003 2004 2005 2006 2007	13,600 lbs 13,600 lbs 16,400 lbs 16,400 lbs 16,400 lbs	13,300 lbs 13,300 lbs 16,100 lbs 16,100 lbs 16,100 lbs	12,900 lbs 12,900 lbs 15,900 lbs 15,900 lbs 15,900 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×4	2003 2004 2005 2006 2007	13,300 lbs 13,300 lbs 15,900 lbs 16,000 lbs 16,000 lbs	12,900 lbs 12,900 lbs 15,600 lbs 15,600 lbs 15,600 lbs	12,700 lbs 12,700 lbs 15,400 lbs 15,400 lbs 15,400 lbs

Automatic Transmission F-250/F-350 Superduty SRW Towing Specs

Automatic Transmission Spec Types	Year	F-250/F350 SRW Regular Cab	F-250/F-350 SRW SuperCab	F-250/F-350 SRW Crew Cab
Max Conventional Tow Capacity 4×2	2003 2004 2005 2006 2007	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lb 12,500 lbs 12,500 lbs
Max Conventional Tow Capacity 4×4	2003 2004 2005 2006 2007	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs	12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs 12,500 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×2	2003 2004 2005 2006 2007	13,700 lbs 13,700 lbs 16,500 lbs 16,500 lbs 16,500 lbs	13,300 lbs 13,300 lbs 16,100 lbs 16,100 lbs 16,100 lbs	13,100 lbs 13,100 lbs 15,900 lbs 15,900 lbs 15,900 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×4	2003 2004 2005 2006 2007	13,300 lbs 13,300 lbs 15,800 lbs 15,800 lbs 15,800 lbs	13,000 lbs 13,000 lbs 15,600 lbs 15,700 lbs 15,700 lbs	12,700 lbs 12,700 lbs 15,600 lbs 15,500 lbs 15,500 lbs

Manual Transmission F-350 Superduty DRW Towing Specs

Manual Transmission Spec Types	Year	F350 DRW Regular Cab	F-350 DRW SuperCab	F-350 DRW Crew Cab
Max Conventional Tow Capacity 4×2	2003 2004 2005 2006 2007	13,300 lbs 13,400 lbs 15,000 lbs 15,000 lbs 15,000 lbs	13,000 lbs 13,000 lbs 15,000 lbs 15,000 lbs 15,000 lbs	12,800 lbs 12,800 lbs 15,000 lbs 15,000 lbs 15,000 lbs
Max Conventional Tow Capacity 4×4	2003 2004 2005 2006 2007	12,900 lbs 13,000 lbs 15,000 lbs 15,000 lbs 15,000 lbs	12,600 lbs 12,600 lbs 15,000 lbs 15,000 lbs 15,000 lbs	12,400 lbs 12,400 lbs 15,000 lbs 15,000 lbs 15,000 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×2	2003 2004 2005 2006 2007	13,300 lbs 13,400 lbs 16,400 lbs 16,600 lbs 16,600 lbs	13,000 lbs 13,000 lbs 16,300 lbs 16,100 lbs 16,200 lbs	12,800 lbs 12,800 lbs 16,100 lbs 16,100 lbs 16,100 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×4	2003 2004 2005 2006 2007	12,900 lbs 12,900 lbs 15,900 lbs 16,100 lbs 16,100 lbs	12,600 lbs 12,600 lbs 15,800 lbs 15,600 lbs 15,800 lbs	12,400 lbs 12,400 lbs 15,600 lbs 15,600 lbs 15,600 lbs

Automatic Transmission F-350 Superduty DRW Towing Specs

Automatic Transmission Spec Types	Year	F350 DRW Regular Cab	F-350 DRW SuperCab	F-350 DRW Crew Cab
Max Conventional Tow Capacity 4×2	2003 2004 2005 2006 2007	13,400 lbs 13,400 lbs 15,000 lbs 15,000 lbs 15,000 lbs	13,000 lbs 13,000 lbs 15,000 lbs 15,000 lbs 15,000 lbs	12,800 lbs 12,800 lbs 15,000 lbs 15,000 lbs 15,000 lbs
Max Conventional Tow Capacity 4×4	2003 2004 2005 2006 2007	13,000 lbs 13,000 lbs 15,000 lbs 15,000 lbs 15,000 lbs	12,600 lbs 12,600 lbs 15,000 lbs 15,000 lbs 15,000 lbs	12,400 lbs 12,400 lbs 15,000 lbs 15,000 lbs 15,000 lbs
Max 5th-wheel/Gooseneck Tow Capacity 4×2	2003 2004 2005 2006 2007	13,400 lbs 13,400 lbs 16,700 lbs 19,200 lbs* 19,200 lbs*	13,000 lbs 13,000 lbs 16,300 lbs 18,800 lbs* 18,800 lbs*	12,800 lbs 12,800 lbs 16,100 lbs 18,600 lbs* 18,600 lbs*
Max 5th-wheel/Gooseneck Tow Capacity 4×4	2003 2004 2005 2006 2007	13,000 lbs 13,000 lbs 16,200 lbs 18,700 lbs* 18,700 lbs*	12,600 lbs 12,600 lbs 15,900 lbs 18,300 lbs* 18,300 lbs*	12,400 lbs 12,400 lbs 15,600 lbs 18,100 lbs* 18,100 lbs*

2003-2007 Ford Superduty 6.0L Powerstroke History

Best Ford Superduty 6.0L Powerstroke Upgrades

Since the 2003-2007 Ford Superduty with the 6.0L Powerstroke V8 Diesel engine has been around for many years now, we’ve learned a lot about what can both improve their durability and lifespan, as well as what you can do to improve their performance. In this section of our guide we’ll explore what upgrades can be done to both make your truck last longer, and how you can increase horsepower, torque, and throttle response.

Top 6.0L Powerstroke Upgrades for Improved Reliability

Top 6.0L Powerstroke Performance Upgrades For Improved Power

The 6.0L Powerstroke comes from the factory producing 325 horsepower and 560-570 lb.-ft of torque. While these numbers were incredible at the time, these are only a fraction of what modern-day diesel engines like the latest 6.7L Powerstroke engine can churn out. Fear not, however, there are a multitude of aftermarket solutions that can improve 6.0L Powerstroke Performance, fuel economy, and throttle response dramatically! Check out some of our favorites down below.

For more 6.0L Powerstroke upgrades, visit our post, The Best 6.0L Powerstroke Powerstroke Upgrades.

Most Common 6.0L Powerstroke Problems

While I only included three problems that are frequently encountered with this engine in this post, there are actually many more problems that can occur. Check out our comprehensive guide with the most common 6.0L Powerstroke problems and how to fix them in our Most Common Ford Superduty 6.0L Powerstroke Problems post.

2003-2007 Ford Superduty 6.0L Powerstroke Maintenance

One of the best ways to make your 6.0L Powerstroke more reliable is by properly maintaining your truck. Due to the EGR process, your system’s coolant and engine oil are under significantly more strain, especially if your truck is used for heavy towing, or if it’s modified with aftermarket products like tuners. Even stock trucks that operate under minimally harsh conditions experience problems at some point. That’s why it’s absolutely critical you perform 6.0L Powerstroke maintenance frequently, and that you use the best fluids, oil, and filters possible.

In this section, we’ll provide a brief overview of how to maintain your 6.0L Powerstroke-equipped Ford Superduty truck.

6.0L Powerstroke Service Intervals

One of the most important things to keep in mind when it comes to 6.0L Powerstroke maintenance is that just because of your truck’s engine design, we recommend following the severe maintenance schedule. It requires more frequent service, but your truck will thank you for it. It’ll help keep your truck on the road for a longer period of time.

Maintenance/Service Type	Miles	Kilometers
Change Oil	5,000 miles	8,000 km
Change Oil Filter	5,000 miles	8,000 km
Change Fuel Filter(s)	10,000 miles	16,000 km
Replace Air Filter	Check Filter restriction gauge. Replace as necessary.	Check Filter restriction gauge. Replace as necessary.
Flush Cooling System	Every 40-50,000 miles or once every 1-2 years.	64-80,000 km or once every 1-2 years.
Replace Auto Transmission Fluid	30,000 miles	48,000 km
Replace Manual Transmission Fluid	60,000 miles	96,000 km
Change External transmission filter	30,000 miles	48,000 km
Change internal transmission filter	30,000 miles	48,000 km
Replace Transfer Case Fluid	150,000 miles/ 60,000 miles under severe operating conditions	240,000 km/96,000 km under severe operating conditions.
Replace Rear Differential Fluid	100,000 miles/ 30,000 miles under severe operating conditions	160,000 km/ 48,000 km under severe operating conditions
Replace Front Differential Fluid	100,000 miles30,000 miles under severe operating conditions	160,000 km/ 48,000 km under severe operating conditions

2003-2007 Ford Superduty 6.0L Powerstroke Fluid & Oil Capacity

Oil/Fluid	Capacity – Quarts	Capacity – Liters
Engine Oil	15 Quarts /w filter	14.2 Liters
Auto Transmission Fluid	17.5 Quarts	16.6 Liters
Manual Transmission Fluid	5.8 Quarts	5.5 Liters
Transfer Case	2 Quarts	1.9 Liters
Engine Coolant	27.5 Quarts	26 Liters
Front Differential Fluid (Dana 60)	3 Quarts	2.8 Liters
Rear Differential Fluid Sterling 10.50″ Dana 80 Dana S110 Dana S130	See Below 3 Quarts 3.5 Quarts 6.98 Quarts 6.98 Quarts	See Below 3.3 Liters 4.0 Liters 6.6 Liters 6.6 Liters

2003-2007 Ford Superduty 6.0L Powerstroke Oil, Fluids, and Maintenance Parts

6.0L Powerstroke Engine Oil

Engine oil type	Outdoor Ambient Temperature	Part # Buy it on Amazon	Part # Buy it at Walmart
SAE 15W40	Acceptable at temperatures over 10 degrees Fahrenheit. Recommended Oil for temperatures over 30 degrees Fahrenheit.	Motorcraft XO-15W40-5Q3SD	Motorcraft XO-15W40-5Q3SD
SAE 10W30	Preferred engine oil at temperatures between 30 to -10 degrees Fahrenheit. Acceptable at temperatures from -10 to 90 degrees fahrenheit.	Motorcraft XO-10W30-5Q3SD	Motorcraft XO-10W30-5Q3SD

6.0L Powerstroke Filters And Fluids

Part Type	Part #
Engine Oil Filter	Ford: 3C3Z-6731-AA Motorcraft FL-2016
Oil Filter Cap	Ford: 3C3Z-6766-CA Motorcraft EC-781
Fuel Filter	Ford: 3C3Z-9N184-CB Motorcraft FD-4616
Engine Air Filter	Ford: 4C3Z-9601-AA Motorcraft FA-1778
Coolant	Concentrated : Motorcraft VC-7-B Diluted: Motorcraft VC-7-DILB
Automatic Transmission Fluid For TorqShift 5R110W Trans	Motorcraft Mercon SP ATF
Manual Transmission Fluid For ZF	Motorcraft Mercon V
External Transmission  Filter	Motorcraft FT-145  (Re-Use your O-Ring)
Internal Transmission  Filter	Motorcraft FT-144
Transfer Case Fluid	Motorcraft Mercon V
Front Differential Fluid	Motorcraft SAE 80W-90 Premium Rear Axle Lubricant XY-80W-90–QL
Rear Differential Fluid Sterling 10.50″ Dana 80 Dana S110 Dana S130	See Below *(May need to add Additive)* Motorcraft SAE 75W-140 XY-75W140–QL  Motorcraft SAE 75W-90 XY-75W90–QLS Motorcraft SAE 75W-140 XY-75W140–QL Motorcraft SAE 75W-140 XY-75W140–QL

Looking for more Ford Superduty 6.0L Powerstroke Maintenance Information? Visit our Comprehensive Ford Superduty 6.0L Powerstroke Maintenance Guide.

2003-2007 Ford Superduty 6.0L Powerstroke FAQs

Check Our Other Ford Superduty 6.0L Powerstroke Posts

• Comprehensive Ford Superduty 6.0L Powerstroke Maintenance Guide
• Best Ford Superduty 6.0L Powerstroke Upgrades
• Most Common Ford Superduty 6.0L Powerstroke Problems & How to Fix Them

Article Sources

• 2003 Ford F-250, F-350 Super Duty Brochure, Ford Motor Company, 2002. 
• 2004 Ford Superduty Brochure, Ford Motor Company, 2003. 
• 2005 Ford Superduty Brochure, Ford Motor Company, 2004. 
• 2006 Ford Superduty Brochure, Ford Motor Company, 2005. 
• 2007 Ford Superduty Brochure, Ford Motor Company, 2006. 
• “The 6.0L Power Stroke Engine.” Powerstroke Diesel, Ford Motor Company, powerstrokediesel.com/engine6.0. Accessed 25 Sept. 2023. 

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