2003-2007 Ford Powerstroke EGR system - where it is, because there is a problem, and what you can do about it
In 2003 Ford introduced the 6.0 Powerstroke in the world. This is the same motor, the International VT365 calls. This engine has received a bad reputation in the world of diesel engines because of reliability problems. Encounter a problem area here today, the EGR system.
Before going any further, please understand that the EGR system is a unit of emissions. It is against federal law to tamper with, remove or make an emissions-based system unusable. Please understand that allThe information in this article have been collected from off-road only, and I do not agree with removal or manipulation of the emissions of a vehicle used on public roads. All information gathered for this article from the testing of vehicles on our Superflow engine dynamometer in the shop. It is up to you and your mechanic to determine what steps you will take your truck with the change. Use this information at your own risk).
1 What is the EGR system and why do I needright?
One of the most common questions I get is, what is the EGR system and why do I need? We have a long technical descriptions can be found here. EGR stands for exhaust gas recirculation. Certain emissions standards, it is necessary to introduce gas into the air intake again, to bring some elements in the levels of waste in this year's truck series. Of course you do not want to download directly into the hot exhaust manifold, thenTherefore, there is an EGR cooler. The radiator coolant is running through it and looks very much like a normal radiator or radiators. The exhaust gas passes through this bit 'and cooler lowers the exhaust gas to a temperature that can be introduced into the intake system. On 6.0 Power Stroke engine, is a very simple system consisting only of a capacitor and a valve. If the engine computer decides the EGR valve should open under certain conditions, theDrain the radiator and leave the intake manifold. Here comes the first sign of a problem that the exhaust gas is always in the EGR cooler.
2 What has gone wrong with the EGR system and how it can damage my engine?
The big problem here is the heat. This is a completely stock engine exhaust temperatures over 1000 degrees to produce. So imagine, 1000-1500 degree air through the radiator and runs continuously every day. How longDo you think it would take? Then, put the radiator in a closed box, not only to withstand the high temperatures, but 10-50 psi of back pressure, which is before the turbo and exhaust manifolds are integrated. Even if the radiator is made from materials that are designed for high temperatures, is not a question of if, but when your cooler will fail. In the best case scenario is that the losses a little cooler 'of coolant in the exhaust system and there is discharge andonly to discover that a loss of coolant. Worst case scenario is, the pressure of the exhaust gas can enter a pause in the cooler and give you the coolant, which only operates at 12 psi or so max. The high pressure cylinder head gaskets and ruin the oil cooler. They were never designed to withstand that much pressure in the cooling system. Also can not keep the cooling system cool in the truck with so much pressure. For this reason we hear about or have experienced vomiting coolant from the capDegas bottle after pulling a load along a hill. The cap is to bleed off pressure from about 12-14 psi. The temperature of the coolant, and more extra pressure from the exhaust is pushed into the coolant is directly express the cap. We have a truck in the garage now with a blown head gasket and EGR cooler. The pressure in the cooling system had become so high that it blew directly into a tube for the coolant bottle. This truck was a work truck bone. This is just blown radiator problemWorse, if you put a programmer on the truck, raises exhaust temperatures several hundred degrees. If you set the scheduler on the highest setting, attach a heavy trailer, and then pulling it down a degree, I recommend it to your mechanic for speed selection. You will need his services as soon as possible.
The other problem with the system is that the EGR valve increases steadily with the exhaust soot coke. The exhaust gases dirty sooting on the surfaces of the valve. Sooner or laterValve enough to get soot on them that close and not functioning normally. The gas is constantly pouring into the intake manifold now. This condition leads to serious problems of handling, poor fuel economy and low power consumption. If you are a 6.0 Powerstroke for a long time in possession, has no doubt have replaced, cleaned, or have you checked your EGR valve because of this problem.
3 What can we do to solve this problem?
There are some fixes for this problem. The first and most obviousSimply remove the radiator. Unfortunately, this would be against the law. We sell a kit to do just that EGR delete when you use your truck for off-road only. This kit completely removed the radiator from the truck. There is a coolant line, where it came directly from the oil cooler to where it once came from the intake manifold EGR cooler bypass. There is also a tube that replaces the factory-line between the exhaust manifold and turbocharger. A few yearshave a shovel to help in the exhaust pipe directly into the factory radiator. Since the radiator should not be there anymore, we need the tube with a flange which does not replace the radiator to the bucket again. There is some debate about how much difference in performance to replace the pipe actually makes, but I personally just want the stupid ball from there if it were my car. In addition, we are removing more than a place to lose a discharge were not left the radiator factoryFlange with a sort of block out of it.
The other solution is to replace the radiator with a "performance" that is not likely to break. Personally I have never installed one of these myself. I really do not believe in them. Even though the cold will never be a better device then pop, it would still drain suction. If you've ever pulled on a Powerstroke 6.0, would be the amount of soot collected to be excited about the passage of entry and registrationValves. Leaving dirt in the exhaust manifold to a bad idea all around. If you're on a tight budget, still under warranty, or worried for no cooling issues, you can only block the stock heatsink. The fastest and best low budget solution is to put a freeze on the ends of the radiator cap and weld them tight. In this way, can not exhaust the coolant can not solve if the radiator is still torn. You do not have the dilemmaShovel in the exhaust pipe, but this correction low dollar is ok if you can not afford to remove the kits to do it well. With that being said, I would still install the kit on my truck bypass staff to get rid of the mess too good.
4 will be the elimination of the radiator on the way my race truck? I get a check engine light?
The answer to the first question is yes. You should increase fuel economy, a little 'faster spool the turbo, and usually a bit' lowerEGT. There are no negative performance effects of removing the radiator, no matter what Ford says the technician friendly. It seems a waste of money to a system of high-flow intake air filter or cold air to install if you hot, dirty exhaust gas flow to the system are just the latest. Regarding the check engine light, you should not arrive at all until you leave the EGR valve is inserted into the manifold and there is absolutely no reason to remove them from the system oncefrom the radiator. The computer to open and close as often as he wants. There is no feedback to know if the computer did in the exhaust manifold when the valve is open permissions. The computer is happy, only the opening and closing the light valve will and without any check engine light. There are some kits are clear, one block off the edge is the port where the EGR valve is. I advise you to install. For starters, there areWhy stop when the radiator, there are no exhaust gases can be removed to get through the valve. Secondly, you must leave the valve is inserted and the installation on the engine to prevent engine check light, which is a kind of amateur at best.
5 Can I do anything to prolong my life, EGR cooler, if I want to leave, right?
If you do not want the radiator out of fear of blacks and helicopters moved into a prison for tampering with equipment on federal issues, there are someWhat you can do. First, the minor to keep your exhaust gas temperatures, the better. The installation of an exhaust system to reduce the high EGTS considerably. A intercooling greatest efficiency, such as banks or Technicooler Spearco update will also help. The installation of a turbo as the air moves as stage 1 Garrett EGTS also decrease. And finally the installation of a pyrometer to monitor exhaust temperatures can go back when the gas is too high.Also be sure to run the oil that the law will help your engine for certification, a bit 'of soot on the bottom.
Finally, I firmly believe all the horror stories of more blown cylinder head gaskets on two things be liable: first, the weather is extremely high in some of the first performance of programmers that have been introduced. Simply did not know immediately that the 6.0 would throw up the seals, when more than 12 degrees was used for timing of programs really hot. The 7.3 's roseso long and no problem. Secondly, I believe, helped blown EGR cooler then and what still blown cylinder head gaskets today. I understand the need for cleaner emissions, but at what cost?
Thanks for reading,
John Anderson
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