6.0L EGR COOLER DELETE AND OIL COOLER ISSUES

powerstrokehel...
Archoil: archoil.powers...
A conversation about the EGR cooler and oil cooler and their role in 6.0L engine damage/meltdown. Also solutions to solve these issues so you will not have these problems.

[@j.r.w7636]

Egr delete and complete bulletproof on a f250 power strike after 200 miles lol. Took me a entire week doing it myself. Years later I’m at 310 going strong.

[@jaychristensen4600]

I have a stock 04 F-350 crew cab 4X4 Centurion, 150K miles, never any serious issues but have been concerned with the EGR cooler stories. I bought a replacement EGR cooler, took to a machine shop where they charged me $40 to weld ends shut. It took me about 15 hours of Labor over the weekend (disassembled & cleaned turbo at the same time) I followed the advice of this video exactly and I am shocked with the difference. Couldn't be happier! Thanks!

[@tommybragalone1350]

Jay Christensen did you notice a difference in the performance?

[@colemorris766]

did you experience a problem with power loss?

[@powerstrokehelp]

The EGR tends to get gummed with the older fuel, but the VGT is more affected by lack of use. The vanes actually rust to the housing.

[@powerstrokehelp]

I actually dont recommend welding the EGR coolers in a 6.4L at all. THe EGR cooler passage is also used as a popback valve for your turbo. If you block the system you run the risk of shearing the shaft on your turbo.

[@masonpedraza6234]

But welding the EGR COOLER on a 6.0 is okay right?

[@thekosmokramer]

@@masonpedraza6234 right??

[@hickindustries7076]

egr? more like boost leak

[@matty86suk]

The 6.0 is a joy to work on with the cab off.

[@powerstrokehelp]

Call 770-931-4070 and ask for Dana, he can fax you a quote for all that you want done.

[@smilen8tiveify]

Is there a email ?

[@powerstrokehelp]

@Oilmanhenry The truck is running too cool and staying in warm up mode (pouring more fuel). You may need to cover part of the radiator in the winter, like the old school truckers.

[@Paladin_of_Justice]

hey ferkemall do you live in the U.S. Some people try and attempt to make the world a better place. it doesn't always work out. America is the land of dreams,progress,and freedom (dwindling down fast I grant you) egr on diesels don't make sense yet. they cut power,performance and even fuel mileage not to mention other costly mechanical problems. what does Renault do for the world ? the air quality ?, dependence on fossil fuel etc ? Now I'm not a tree hugger but I don't want my children mucking around from the polluted emissions left by a Renault or a ford . I think all of mankind across the globe wants dependable pollution free transportation . And remember this my ford hauls cattle, pigs, and farm produce not to mention organic grains and feed for livestock . When I see a "Renault" that's the equivalent to my 05 Ford F350 4x4 dually that hauls 20,000 lbs through mud,rock,and hiway then please let me know . Until then take your ponytail and head back to pot smoking amsterdam.

[@powerstrokehelp]

Dont let your coolant level drop. I would run with the coolant cap loose so the system does not pressurize.

[@pinkbandit133]

really? so dont get a new coolant cap??

[@powerstrokehelp]

@Oilmanhenry I have found it best to leave it in and plugged in especially in 05 and later 6.0s. When the truck is first started the PCM performs a complete diagnostic of the electrical system. The PCM will find the EGR valve unplugged it sets a code. Some tuning programs will over ride this. I prefer to leave it so the diagnostic is completed successfully and then the tuning never opens the valve. It is far more effective with less drivability problems in the long run.

[@powerstrokehelp]

It is two separate problems. The cold start is probably a bad injector or two. The hot start is a leak or a worn out pump or bad injector seal. Id have to see it to be sure.

[@powerstrokehelp]

@FordToughDiesel You need to check out the truck thoroughly. See if it has a goose neck or fifth wheel. If it has been pulling hard it may need some attention soon. OR just figure a bulletproofing into the budget and get it done and ride with confidence. NOBODY sells a perfect truck that does not need anything. The probability is high that it has an issue that may or may not be obvious.

[@dwongu]

I just wanted to say that I love this channel. You do a great job of explaining the complexities of the PowerStroke to guys like me.

[@powerstrokehelp]

@mtrapuzzano1 You really need EDAS if you are towing heavy in the heat. Go to the POWERSTROKEHELP (dot) COM website, you can get more info and order it there.

[@powerstrokehelp]

You should be good. What is the EOT under load? Does it go over 250? If so it may be time for an Oil cooler.

[@powerstrokehelp]

@Compwhiz128 In the dirty south it is a non issue because no one tests diesels. The problem with the Bullet proof system is that heat STILL gets into the coolant but it is a more durable unit for folks living in CA or other area that tests diesels.

[@powerstrokehelp]

You are better off to stick with factory ford filters

[@powerstrokehelp]

The truck will pass visual inspection, but not the electronic test. If you live in an area that tests diesels the I would consider the Bulletproof EGR cooler from Bulletproof diesel

[@powerstrokehelp]

It helps but the answer is NO. You need to keep the exhaust heat from transferring into the engine coolant. The only way is to block the cooler.

[@powerstrokehelp]

If you have an 06 or 07 you will need to reflash the PCM with an EGR off tune. Otherwise the check engine light will come on. Bill at Powerhungry can help. PHPTUNE (dot) com

[@MikeTauroRules]

Hey Bill, quick question, does keeping the EGR valve shut have the same benefit as doing a full on EGR block off? Thanks in advance

[@powerstrokehelp]

@johnygogo It would cost too much money. They already have had to sue Navistar for $850m+ to offset the warranty claims. Watch my vid on 6.0 THE PERFECT STORM. Thats alot of cheese.

[@powerstrokehelp]

@jerbrerizz94 Its not that the system doesn't work. We just had a reliability issues in a fleet situation where the driver wasn't keeping an eye on the truck. So there was damage done and we were the bad guys.

[@michaelovitch]

Why don't they use a separate cooling system for the egr ? i think to a specific radiator and expansion tank.

[@michaelovitch]

@powerstrokehelp i know. i want to say it could be good and allow to avoid engine damage if there was a separate coolant system for the egr stuff. no ?

[@powerstrokehelp]

@thebird95632 Alot of folks swear by the coolant filters but if the coolant is changed every 30k miles or so you should be OK.

[@powerstrokehelp]

If you have an 05 and earlier it is no problem. If you have 06 and later the blocked EGR cooler will set the MIL code.

[@michaeljkasnter]

Iam starting to believe Emissions have destroyed any chances of a modern Diesel engine of being reliable

[@powerstrokehelp]

Generally but not always stock trucks have fewer problems. Injectors will fail with poor fuel filter maintenance or incorrect filters. Look at my "3 Fs" video.

[@powerstrokehelp]

@1curt12 Where exactly would you buy a gauge that can handle a glycol environment? I've been at this for going on 5 years and it is not as easy as it seems.

[@powerstrokehelp]

@dragracer3 If the EGR is leaking coolant it is only going to get worse. Do you have coolant coming out of the tail pipe?

[@powerstrokehelp]

You cant run a delete in the Peoples Republic of California or any other jurisdiction that requires emissions testing on the Medium duty pickup truck.

[@powerstrokehelp]

@pianoman9441 I think it a great system. We have installed several with great success. The system is overkill unless you are pulling hard all the time.

[@powerstrokehelp]

Warm up the truck and release the pressure and retest. You will probably find it wont go over 5-6 psi.

[@powerstrokehelp]

@mrlaroney Gotta take a big patience pill to work on a van. I'd forget about the kit because they can leak coolant. Just remove your cooler and have it welded shut. It looks stock and it wont leak.

[@jamesfenton7338]

Some folks think the 6.0 is indestructible, and you can't help people like this. People like this have to learn the hard way, don't be left holding the bag, inform them that they are responsible, even with "Bulletproof" parts, people will find a way to destroy the engine.

[@powerstrokehelp]

after market should be fine but the factory one will support the exhaust correctly and not cause an expensive Y-pipe failure.

[@powerstrokehelp]

Yep. you need to run the BulletProof EGR cooler. It is an updated heavy duty unit that can handle more abuse.

[@ploxplox1109]

Hey I have 2007 Ford F-250 XLT 6.0 can you give me a Estimate to bulletproof my truck don’t tow a lot but I daily drive it a lot and I want it to be very Reliable and currently live in Hinesville GA I think it’s a 4 hour drive to you

[@MyBlowncobra]

@@ploxplox1109 to totally bulletproof it from head to toe...it's about 15k

[@powerstrokehelp]

Just in case the EGR cooler it self is bad or goes bad, this will keep the coolant from going into the engine.

[@hemimofo111]

why do u need to block both ends on the cooler, can you just weld a cap on just one end?

[@powerstrokehelp]

I dont like hammering a plus into the stainless EGR cooler as it may crack. Welding the plug is safer.

[@johnygogo]

How come Ford doesn't do a re-call? I think that's what most people don't understand about these engines.

[@powerstrokehelp]

Keep a close eye on your coolant level. Check it every fill up. If you have coolant loss it is time to be aware that you may have a problem.

[@powerstrokehelp]

@Bullshitkorner Yes just weld the one you have and a BIG YES to replacing that oil cooler. It is cheap insurance when you already have it apart.

[@powerstrokehelp]

@oilburner05 Jim at Engine Services in Braselton Ga.770-967-7878

[@powerstrokehelp]

The coolant will still be exposed to exhaust heat unless the back of the cooler is blocked.

[@powerstrokehelp]

@irongiant101 The coolant continues to flow through the cooler, only the exhaust flow is welded shut.

[@powerstrokehelp]

@cubkid411 i don't sleep much, my brain is always on and working.

[@powerstrokehelp]

Some folks keep an extra valve around. Or you can use a tuner to switch back to emissions tuning during testing and after the test switch back to emissions off tuning that never opens the valve.

[@powerstrokehelp]

Yes you need tuning to shut off the electronic side of the EGR valve.

[@powerstrokehelp]

check out the Dealerproof video. I would consider the basic DealerProof for your truck.

[@stevenmitchell6347]

Navistar uses CAT EC-1 ELC in their versions of these engines with the same EGR and oil coolers, and they don't have the issues of the Fords with the precipitating coolant they DEMAND be used or you void the warranty! Unfortunately, deleting or defeating the EGR system is ILLEGAL and states are beginning to crack down on the practice. Best to replace with the new, stronger design, new oil cooler, coolant filtration system, and use the coolant specified by the manufacturer, NAVISTAR,...CAT EC-1 ELC after a complete flush and back flush of the complete system. 😊

[@powerstrokehelp]

As long as it is welded correctly and sealed you can use a cracked one.

[@powerstrokehelp]

It is not necessary to take the guts out and you want to use stainless.

[@powerstrokehelp]

@f350powerstroke It is a great unit but heat still gets in your engine coolant.

[@flt89]

Bill - Thanks for great information. I have an 05 and have done the EGR cooled delete, 4" exhaust, upgraded fuel pressure regulator, SCT programing, Amsoil bypass oil filter, and of course new coolant cap. I have the same problem as in another post where I have lost 6 to 7 mpg from when the truck was stock. If, like you said, the engine is running too cool, what temp should it be running at and where is a good place on the block to install a gauge? Should I be running a higher thermostat?

[@pedropunjabi7339]

flt89 Did you ever figure it out? Im looking to buy a 2005 6.0 but not sure

[@powerstrokehelp]

It is not necessary to take the guts out and you want to use stainless.

[@powerstrokehelp]

@tgaliger You have to block the cooler also or all your boost will escape it the EGR valve opens.

[@aterack833]

Given that failure modes of complete sudden stalling exist, a better system would just shut down the engine if that problem came to be, and a light saying it’s what caused it would be all it would take to stop people from thinking it’s anything else

[@powerstrokehelp]

I dont know if you need a valve unless I test it. But changing/cleaning appear to be the best route in an emissions area.

[@powerstrokehelp]

@thebird95632 EDAS is very easy to install. There is an EDAS install vid on youtube.

[@ianvala2564]

Tried your website would not work. 05 excursion Texas here we had a freeze bought this truck belive it had water in coolant do to had to replace waterpump and then. A plastic y connector. Then it was fine fast-forward two days later had a really hard time starting then tons of white smoke till I could get home no power loss what so ever did not overheat. Waited a day checked coolant degass bottle was empty. Brand new bottle and all new coolant. 275xxx all stock. Question is I am worried the cooler internal cracked and let coolant into the exchaust. Is that possible or failing egr valve could cause this. Got hoodwinked by the guy who sold it to me. Spent thousands already.

[@powerstrokehelp]

The EGR valve stays. It needs to be plugged in at initial start up so that the computer "sees" it. After the truck has run for a moment the computer goes to open loop (loaded computer program) where it reads sensors and makes adjustments. At this point the EGR valve is never opened by the computer.

[@powerstrokehelp]

No You must have a functioning EGR cooler to pass emissions tests. I recommend the Bulletproof diesel EGR cooler.

[@powerstrokehelp]

@DragosZK It is best to weld the cooler and do the EGR off tune. Also replace the oil cooler while you have it apart.

[@rickmendez1139]

powerstrokehelp Can you recommend a better aftermarket oil cooler than the factory unit? Thanks!

[@powerstrokehelp]

@whereispg I actually drove to work in the same car today. It is the perfect car for my teenage daughter. Love the car but EDAS is not necessary in this application because there is no EGR system and the head gaskets are not at risk.

[@powerstrokehelp]

@nickelwork87 I think it is an excellent product. I have installed several and been impressed with the quality.

[@powerstrokehelp]

It the coolant bubbling out of the passenger manifold?

[@powerstrokehelp]

Possibly a FICM but check out my RevX vid

[@powerstrokehelp]

@dragracer3 Or weld the one you have. We just keep a stack of them here and rotate them through to the welding shop.

[@clintroughton1423]

I did the sinister style at 46,000 miles and a Hypertech Max Energy, 5" exhaust w/ 4" down pipe, fuel pressure spring upgrade, Amsoil external bypass oil filter and have had to only replace the FICM @ 99,000 and IPC sensor twice but invented a specialty socket the second time i replaced it. I have total confidence in my 6.0. Its got 3.73 gears and choose not to Highway drive above 75mph keeping the rpms about 2100. I just bout another 6.0 F-450 and am going to do every thing but full exhaust. It has 167,000 miles so I'm getting it late but i feel not to late to save it. However the gears in the 450 are 4.88 and at 65mph the rpms are at 2400 this sucks but Im not pulling heavy loads and the terrain around where i live is flat compare to the mountains in Ky and Tennessee . I've always felt that the egr was the source of the problem but never heard anyone else lead off with it till now. Thanks for the videos .

[@powerstrokehelp]

@fordpowerstroke2012 Make sure they can weld high quality stainless.

[@Pickle117]

could a blown egr cooler cause a p0299 code, i have no power from my turbo. Its leaking coolant and blowing thick white smoke out the exhaust

[@davidlaing4193]

Thanks for the Excellent video. Coolant disappearing in my 04. looks like a heck of a project. whats is you opinion of the "bulletproofdiesel" EGR cooler as well as oil cooler? Thanks

[@daviddealba9886]

I have a question ,I have a customer that bought a 07 f250 with a 6.0 and it had just go item the head gaskets replaced ,but they did not replace the head bolts .my question is this can the head bolts be replaced one at a time or do the head gaskets need to be replaced

[@powerstrokehelp]

call the shop at 770-931-4070

[@powerstrokehelp]

@michaelovitch No EGR cooler uses engine coolant.

[@MarcOppelt]

My cooler is in great condition, so I TIG welded it closed on both ends and reinstalled it. Just like the video says. This is a better solution. There is NO WAY any coolant will ever get to the intake tract, even if the coolant side of the this heat exchanger were to fail.

[@johnpage1001]

I'm thinking of doing the same thing. was it stainless or aluminum? what diameter and thickness pieces did you use to weld it shut? also, did you use a tune to turn off all the egr stuff off, or leave the programming alone?

[@powerstrokehelp]

@mttbear You want to block the cooler to keep all heat out of the coolant.

[@marioncobaretti2280]

egr codes are the next problem

[@MrLeviaFUN]

marion cobaretti , what codes? An egr valve is either shut or open. As far as I know, it doesn't sense if anything is going through it

[@mattorton1471]

05-07 will eventually throw a p0401 code. Need an SCT tuner 7515 to disable it.

[@edwardman1742]

I have a problem with this EGR delete solution. DISCLAIMER: I’m not a mechanic, so I can be totally mistaken. The problem with this solution is that the coolant is still circulating through the EGR. If the EGR is blown or eventually ruptures, you have the serious problem of coolant filling the exhaust portion of the EGR and then contaminating the coolant system with exhaust soot. Also, you will still have the exhaust flange and “scoop” that directs exhaust gas. So you’re more likely to have an exhaust leak from the blocked-off end and you’re also hindering your exhaust flow by keeping the scoop in tact. Lastly, this is only a cheaper solution if you are a welder or have easy access to one. It seems to me that total removal and bypass is still the best option. Just find a supplier that offers a good leak resistant clamp set up. It’s a clamp. That’s an issue that shouldn’t be too hard to overcome. My fellow 6.0 brethren... please chime in if I’m wrong :-)

[@aimless-drifter]

when EGR cooler is blocked off from hot exhaust gases it's chance of rupturing 100x lower. Also as he was explaining in the video that "scoop" is necessary as it keeps the exhaust pipe from wobbling and braking stuff

[@bob14219]

why doesnt anyone come up with a chemical to pump thru the partially plugged oil cooler that dissolves the precipitated deposits and fixes the problem ?

[@fastst1]

oxsalic acid works decently well but it won't work all the time, if its badly plugged you can try rinsing it out, garden hose spray with lots of bubbles and force. A little acid rinse and flush, repeat. If you have lots of junk its like cars in a parking lot, it'll flow around the debris without moving it.

[@powerstrokehelp]

It is a good piece for those areas in the country that require the EGR to work.

[@antoniomontejano7375]

If I weld the egr what tunes can I use too avoid a cel and still pass California smog

[@BackCountryWrenching]

@powerstrokehelp so it is a stainless piece just a matter of getting some plugs or making some and getting them tig welded in place. Thanks for the tip my truck is off warranty in a year, welding it looks like a cheaper solution , plus replace the oil cooler at the same time.

[@Flightstar]

Im sticking with my old chevy 6.5 turbo. 50 buck injectors and 700 buck injector pumps

[@twag0735]

videoclipits I miss my old 6.5. It wasn't anything crazy, didn't make huge power, but it was also a small truck that was cheap to fix.

[@jerristanley3041]

Love my old 6.5😎😎😎

[@powerstrokehelp]

Call us at 770-931-4070

[@powerstrokehelp]

@mttbear It helps but the cooler needs to be blocked to really be effective.

[@mttbear]

I have a SCT tunner. Why can't I just shut off the EGR valve and not delete it?

[@powerstrokehelp]

More than likely it is head gaskets.

[@jfoley1987]

Anyone know where i can get the steel caps to weld on to the egr cooler ends?

[@powerstrokehelp]

Do the oil cooler. You wont regret it.

[@powerstrokehelp]

If it smells like coolant then your EGR cooler has a crack in it.

[@luminol]

How do you pass inspection and if I get a tune won’t the check engine light stay on if I delete? How do I fix this?

[@powerstrokehelp]

Id take care of it before it gets hot out.

[@siamakaghazeinali]

Hi i have ford e350 6.0 2004 disel win 1FTSE34P34HB19588 , it was making smoke and losing power. i put car in turbo specialist to fix it but they fixed some issues but the car still has power lose and some times showing turbo bark. it seems they can't find problem. i live in North Vancouver canada and i need your help as specialist. now my mechanic asked me to delete egr cooler but i am not sure it will help. You can see his reports by email . i can pay you for your solution Thanks

[@aliabdallah102]

Do they do emissions (smog) in your area?

[@Spahi77]

I have a question, how does Evans Waterless coolant hold up in the Powrstrokes? Have you worked with it?

[@powerstrokehelp]

No it wont blow head gaskets.

[@powerstrokehelp]

pressure test it to make sure the welds are sealed.