6.0L EGR COOLER DELETE AND OIL COOLER ISSUES

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Archoil: archoil.powerstrokehelp.com/
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.

[@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?

[@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.

[@matty86suk]

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

[@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]

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]

@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.

[@mystiqueman366]

props for inventing the EDAS. even though I don't own a truck myself, i am quite aware of the issues with these powerstrokes. I would sure have it if I ever bought a 6.0/6.4.

[@abetoss]

I love your videos. I'm currently waiting for a 2004 F350 to arrive and I would be SO lost without them. Thanks! And I need to find the way of making that oil cooler remote without going $2K... I've done it before with smaller engines...

[@kwbradysanch]

I love all the information you put out there it is a lifesaver..i bought an 04 f350 and the coolant was garbage flushed the system and havent had issues since

[@josephdeerslayer9007]

Bill, have a great idea for a clip, the problems you can (WILL) have if you put DEF into your diesel fuel tank. A good friend got extreamly lucky, he put DEF in while the engine was running, and got some into his engine. Had to replace every sensor in his fuel system and a 30 second mistake turned into a 5K nightmare! Keep the clips coming! Thanks

[@gianmameli4971]

Joseph Deerslayer

[@AkJohn74]

Thanks for your great videos I have a oil leak that showed up on the high pressure oil line fittings thought it was a rear main seal lol yea the valley had a pool of oil thanks again my 02 7.3,has 92 k on it

[@powerstrokehelp]

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

[@eegp84]

Thanks a lot for response. It's greatly appreciated.

[@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??

[@ouarzagprotec1647]

thank you for your expectation

[@MrTrueshoe]

Absolute love this information! Thank you

[@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

[@35057]

Ahhhhh! We had a 2005 or 6 E250 with a 6.0 in it that I ran daily for service calls (Diesel tech/rental service.) It overheated on me once in heavy traffic on a summer day. Found out the fan clipped the harness/wire to turn the fan on. I ran the heat as much as I could, but it still overheated. Temp was fine once I swapped the fan. I changed jobs, and come to find out it blew a HG a couple months after I left. Wonder if the EGR system had something to do with it.Good video! Clear up a lot

[@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

[@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]

@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.

[@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]

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??

[@markymarqca1]

Bill - awesome help. Priceless. I'm currently repairing the no start when hot high pressure oil issues on my 2005 6.0 with 43,000 miles. Since i have the engine apart, i'm considering doing the egr delete per your recommendation to weld the tubes. I also wonder if I should go ahead and change the oil cooler: when i took off the degas unit, there was a considerable amount of black residue on bottom. Is this potentially a sign of precipitate in the oil cooler as well, or unrelated? Thanks again!

[@Lasselkv28]

Thanks for another excellent advise.

[@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]

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

[@Mr.Smith101]

Another tip for your viewers is to check the front of their radiators for debris buildup. As a diesel tech I see it all the time.

[@fordpowerstroke2012]

Hey thanks for the video it helped seen as how I know my EGR cooler has failed and i'm waiting to take my truck into a shop here in canada. Now your experience with the sinister delete kit was interesting and I trust you seen as how you do this day in and day out and also your saving me money with not buying the delete kit. But do I just get a welding shop to weld to plugs into the EGR cooler? and I don't have to tamper with the Y pipe at all just leave it stock correct? Thanks

[@bruth6138]

Hey Bill. Been watching all of your videos for some time. As some of the 6.7s are coming off warranty, are people modifying them to remove the DPF, SCR, EGR cooler, EGR delete? Stuff like that?

[@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.

[@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?

[@hickindustries7076]

egr? more like boost leak

[@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]

@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.

[@southtown2366]

done business with BPD LOVE THOSE GUYS!

[@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.

[@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.

[@FordToughDiesel]

@powerstrokehelp Okay thanks a lot! I think I'll just stick to the 7.3s, we are over here in Etowah county, AL. We have an '01 F-350 with 67k on it, so if I ever have any problems out of it, I'll be sure to take it to Georgia to have y'all work on it. Thanks for the help!

[@spcharwoodv]

I have a question for you about the egr delete you mentioned in this video. I am all about saving money and would like to do the delete were you just welded each side of the egr cooler. Do I need to do anything else with that? Do I leave the egr valve in or can I take it out? I was just hoping you could tell me what all goes into that mod. Thank you. Oh and just wanted to say love all the videos you put up and its very informative helps a lot.

[@BigKidCountry]

AWWW i was going down the road minding my own business and it blue-up HAHAHAHA GREAT VIDs looking forward to bringing my truck to you!! I am in clarksville TN and will be calling soon still saving pennies for long list of work thanks

[@josephdeerslayer9007]

Bill, your clips are very helpful and I refer about every powerstroke owner to your channel. Need more with 6.7s. Have your Engine damage Avoidance System on MY 1997 F-250. If you have one for a Duramax aplication, I would buy one. Keep up the good work.

[@CousinDuoGaming]

Thanks for the reply! So unless I install a blowoff valve for the turbo, EGR delete on the 6.4L can do more damage than good?

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

[@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]

@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!

[@Spahi77]

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

[@powerstrokehelp]

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

[@joeplumber9064]

great info brother

[@Kriswill111]

hey bill! just looking into welding plugs into the EGR system,and noticed some people are using a silverweld to set the plugs.. i believe silver weld has a melting point of aprox 850 degrees and the EGR system runs between 800 to 1200 degrees. what do you use to braze the steel plugs into the EGR system?

[@1970PMD]

Bill, I own a 2008 F250 with 80K. What do you recommend I do? Were those issues corrected for the 6.4? or should I go ahead and weld the cooler as you have explained? Thanks!

[@chur44]

Sorry for leaving it here I just don't know how to contact otherwise and know you're good about replying. Thanks for your time. Ur videos are great

[@MetalheadX45]

I have a 2006 f250 with 178,000 miles. All stock as far as i know and i was wanting to flush the radiator and of course put motorcraft gold back in it just to make sure its in it and not something else the previous owner poured in. It runs great and i have heard from many people to install the egr delete so should i just do the weld method like you have shown before or after i flush and replace the coolant or does it matter when, or should i just leave the truck as it is? Thanks so much!

[@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.

[@Denkha94]

thank you for your response. Bill I want to also ask you. please where can I get metal screened fuel filters instead of the stock paper filters. Nothing has been modified to my truck. everything is stock. I appreciate a response thank you.

[@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]

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

[@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.

[@Denkha94]

2004 f-250 6.0L diesel. thank you.

[@powerstrokehelp]

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

[@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?

[@944own]

I live in TN but we also have emissions testing. Actually went through today. They hook up to obd2 and look under with a mirror. Never even pop hood.

[@powerstrokehelp]

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

[@BigJohn6seven]

I just had the HPOP replaced, along with a new IPR, a new ford oil cooler, and a bulletproof egr cooler. The only thing i want to do now is O- ringed heads, head studs and injectors.... I was told to avoid 175 or 190cc injectors on my daily driver. would a set of 50hp (155cc) be a good option or do you recommend stock injectors? LASTLY what would a bill for that head job and injectors look like?

[@CousinDuoGaming]

Do you recommend welding both vertical and Horizontal EGR coolers for the 6.4L? or would welding the vertical be sufficient?

[@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]

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

[@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 ?

[@Mountain_Paladin]

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.

[@urnzwayzmoove]

Great Video!

[@powerstrokehelp]

@MarineCorpsProud We pressure test every cooler after we weld it to be sure there is no leakage. SO the answer is that is doesn't matter if the EGR cooler is bad if it is welded correctly.

[@kaciebrown5144]

A few questions about sequence the sequence of modifications. Can I get the FICM reflashed and PCM flashed by POWERHUNGRY prior to all this or wait till after? Additionally the SCT tuner from DP tuner you mention in this video I can purchase this tuner and have them create a fuel economy mode? Will this effect the FICM/PCM flash that was done causing it to be a waste? I really want better fuel economy I don't do any towing. Thanks for your time.

[@dodgemayham2536]

Hey, I have a question about the egr delete that you did. So let's say my egr is bad and it has a coolant leak . So then I do the egr delete. So I weld the ends and put it back in I hook up everything and so on. So here is my question so if the egr is bad and leaking if I weld the ends won't the coolant leak out were the egr went bad and collect in the egr or will it just pass through like it normally does. Thank you god bless .

[@Mr.Schitzengigglez]

Makes sense. Just plug off both ends. You've effectively performed a delete. And, your mechanic doesn't have to turn his head too far, just to give you a sticker.

[@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]

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

[@irongiant101]

Since you weld the end shut and re-install the egr cooler do you still install the coolant lines to the egr cooler as they originally are? Or do you plug or bypass the coolant around the egr cooler?

[@powerstrokehelp]

It the coolant bubbling out of the passenger manifold?

[@MikeTauroRules]

Okay will do thanks again

[@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

[@joelsmith5886]

Hey Bill after watching a lot of your 6.0 videos while owning a 7.3 for years I decided I was no longer afraid of the 6.0 and its reputation so I bought a 2005 F250 with 185k . Its very clean good running truck and is 100% all stock and never been torn into. However I want address the egr cooler issues before they become an issue. What are your thoughts on the upgraded egr cooler from Bulletproof diesel? Is it a good alternative? or do would you still recommend plugging the ends of the oem cooler and doing a delete that way?

[@jesseramirez7654]

What should the coolant and oil temps be with egr delete Info would be appreciated

[@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.

[@powerstrokehelp]

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

[@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]

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

[@antoniomontejano7375]

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

[@apexman18]

what happens to the egr valve then? just remove it after welding the egr cooler shut? what did you use to plug the egr cooler? thanks

[@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.

[@powerstrokehelp]

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

[@nickelwork87]

Hey bill what do you think about the bulletproff diesel oil cooler upgrade.Do you think it is worth it and have you ever installed one in a 6.0. Thanks, Nicholas

[@powerstrokehelp]

pressure test it to make sure the welds are sealed.

[@powerstrokehelp]

what year truck? which motor?

[@944own]

Will removing the egr cooler make me fail emissions. We have a test where I live. Thanks

[@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.

[@sgfreak96]

Hi if you do anegr delete will that eliminate the problem or possibility of it happening overall? Also will a truck pass inspection minus the egr?? Please respond!!!

[@bige4457]

2006 f35O Dually 6.0 184k miles, air raid intake, Blue spring conversion, getting ready to install egr delete, coolant filter, and SCT tuner. Truck just started chugging and blowing smoke on acceleration with lack of power till it gets to a certain RPM then just takes off fine. what do you think issue might be? please help

[@whereispg]

Dude I love your videos. I have an OM617 85' Turbo Diesel Mercedes and would love to maybe have an EDAS hooked up to it somehow..8)