Home > System Mechanic Articles > 2003-2007 Ford Powerstroke EGR system – where it is, because it is a problem and what you can do about it

2003-2007 Ford Powerstroke EGR system – where it is, because it is a problem and what you can do about it

September 26, 2010

In 2003 Ford introduced the Power Stroke 6.0 in the world. This is the engine itself, the VT365 international calls. This engine has received a bad reputation in the world due to problems with the reliability of diesel. We address the problem areas of the system here today, the AGR.

Before going further at all, it is understood that the EGR system is a device emissions. It is against federal law to tamper with, remove or render useless a system of emissions. PleaseUnderstand that all information in this article only truck was picked up by off-road and do not agree with the removal or tampering with emissions of a vehicle, the public will be on the roads. All information for this article obtained from tests of vehicles on our Superflow bench in the shop. It's up to you and your mechanic to decide what measures to take in modifying trucks. Use this information at your own risk;).

1. Whatthe EGR system and why do I need?

One of the most common questions we receive, what is the EGR system and why do I need? We have for too long in the technical descriptions can be found here. EGR stands for exhaust gas recirculation. Some emission standards, it is necessary to bring the reintroduction of exhaust gases in the intake to certain elements in the plans within the same year of truck exhaust kit. Of course notdumps hot exhaust gas directly into the intake manifold, so that is why there is an EGR cooler. The radiator coolant is passed through the engine and looks very much like a normal radiator or heater core. The exhaust gas passes through this small cooler and lowers the exhaust gas at a temperature that can be introduced into the intake system a. On 6.0 Power Stroke engine, is a very simple system consisting only of a capacitor and a valve. If the engineComputer decides the EGR valve should open under certain conditions, the exhaust gas is released from the radiator and intake manifold. And here we have the first clue of a problem that the exhaust gas is always in the EGR cooler.

2. What is wrong with the EGR system and how they can hurt my engine?

The big problem here is heat. This is a completely stock engine to produce exhaust gas temperatures of well over 1000 degrees. So imagine1000-1500 study of air and constantly running through your heater core every day. How long do you think would it take? So, I ask, that heater core in a closed box that can support not only high temperatures, but 10-50 psi discharge, which was built before the turbo and exhaust manifold. Although the cooler materials that are designed for high temperatures because it is not a question of if, but when you can not be cool. best case scenario is thatThe cooler a little coolant leak in the exhaust system and go from the exhaust and found that only some loss of coolant. Worst-case scenario, the location is the discharge pressure, cooler, you have a break and enter the cooling system that only runs on 12 or so psi max. The high pressure will ruin the head gasket and oil cooler. They were simply not designed to withstand that much pressure in the system coolant. In addition, the cooling system is not always the truckcool with a lot of pressure, so in the system. For this reason you may have heard or read about sick of coolant from the gas cap on the bottle after Degas pulling a load up a long hill. The cap is made of pressure bleed for 12-14 psi. Increasing the temperature of the coolant and the additional pressure in the exhaust gas of the coolant system directly from the cap, Push Push. We have a truck in the garage now with a cooler and EGR blown head gasket. The pressure in the cooling system had become so high that it blew one of the tubes to the right of the coolant tank. This truck was a truck working on the bone. This problem of cooling breezes even worse if you put a programmer on the truck, increases exhaust temperatures several hundred degrees. If programmers hook put on their highest setting on a heavy trailer, and then took a long note, I suggest you contact your mechanic to speed dial. You will need his services as soon as possible.

The other problem with theis the system> so that the EGR valve is constantly coked with soot. The dirty exhaust gas by the deposit of soot on the surfaces of the valve. Sooner or later the valve enough soot on it that close and can not function normally. Now gas is constantly pouring into the intake manifold. This situation is creating serious problems of handling, poor fuel consumption and low power consumption. If you are a 6.0 Powerstroke for a long time in possession, you can replace without any doubt, or cleaned EGRValve occurred, as the problem.

3. What can we do to solve the problem?

There are some updates for this issue. The first and most obvious, simply remove the cooler. Unfortunately, this would be against the law. Sell an EGR delete kit only do so if you are using for your truck for off-road only. This kit completely removed the radiator of the truck. There is a line that bypasses the coolant, where does the oil coolerdirectly to the point where it was once the EGR cooler in the intake manifold. There is also a tube that replaces the factory up-pipe between the manifold and turbo exhaust. Some years have a shovel to help in the exhaust pipe at the factory cooler. Since the refrigerator is gone, we need the pipe with a flange that does not replace the cooler, even for the shovel. It is debatable how much difference in performance instead of the up-pipein reality it does, but I personally just stupid ball from there, if it was my truck. In addition, we are removing an exhaust chamber no longer have the job of cooling the flange leaves off with a kind of block it out.

The other solution is the cooler with a "performance" that is not to break probably be replaced. I personally own one of these ever installed. I really do not believe in them. Even if the cold is never a better device pop in there, youstill gas in the intake manifold. If you have ripped from a 6.0 Powerstroke is never the amount of soot, which collects and intake valves are excited at the gates of aspiration. Leaving dirty exhaust into the intake manifold is really a bad idea all the way around. If you're on a tight budget, they are still worried about warranty, or on the cooler is not there for the problems you just could block the stock cooler. The fastest and best solution low-budget,provide a freeze plug at each end of the radiator and fix it solid. In this way, no exhaust fumes can enter the coldest yet, an outlet when the radiator coolant always broken. You still have the dilemma of the blade in the exhaust pipe, but this fix is ok bottom dollar, if it can not afford to remove the kit to work properly. With this said, I would still install the kit on my truck bypass staff, almost all the casino for good to discard.

4. If the removal of the cooling system in my own wayTruck Driving? I get a check engine light?

The answer to the first question is yes. You should increase EGT, fuel consumption, a little 'faster than the turbo spool, and usually a bit' lower. There are no negative effects of the suppression of cooling performance, no matter what Ford said the technician friendly. It seems a waste of money to install a high flow air filter or cold air intake system, where hot, dirty exhaust pouring inSystem just past. As for the check engine light, you should not get to leave until all the manifold EGR valve inserted and there is absolutely no reason to remove it from the system as soon as the cooler you were away. The computer can open and close whenever they want. No comments that the computer can know if the exhaust did in the intake manifold when the valve is open. The computer is just happyOpening and closing the valve at will and without the check engine light is on. It 'clear some kits out there that have a block of metal at the port where the EGR valve is. I do not recommend installing them. For starters, there's no reason to block them if you removed the radiator, because nobody can get through the discharge valve have. Secondly, you must enter the valve and the installation on the engine to turn the check engine light, what kind of amateurs to bebetter.

5. I can not do anything to prolong my life to the EGR cooler, if I leave it do?

If you do not want the cooler removed for fear of blacks and helicopters of time in jail for manipulation is the Federal Republic of emitting devices are some things you can do. First, the child can make the temperature of exhaust gases, the better. The installation of a high flow exhaust to significantly reduce the EGTS. A larger intercooler efficiency, such as banksTechnicooler Spearco or update also help. The installation of a turbo air moves more like a stage Garrett also help reduce EGTS. And finally the installation of a pyrometer to keep my eyes exhaust temps will allow you to slow down the gas when they are too high. Also, make sure to run the oil that the certification is right for your engine will help a bit 'of soot is down.

Finally, I firmly believe all the horror stories of more blown cylinder head gaskets can beGuilty of two things: first, time is very high in some of the first performance of programmers that have been introduced. They simply do not immediately know that the 6.0 would throw up the seals, when more than 12 degrees was used for timing of programs is very hot. The 7.3 's get up so much time and everything no problem. Secondly, I believe, has contributed blown cooled EGR and again cause blown head gaskets today. I understand the need for cleaner emissions, but at whatCost?

Thanks for reading,

John Anderson

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