6.0 Dead After EGR Cooler Repair - Ford Powerstroke Diesel Forum
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Old 02-10-2010, 08:51 AM
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6.0 Dead After EGR Cooler Repair

Have a 2005 F250 6.0 PSD that started blowing white smoke. EGR cooler failed. Had a mechanic that said he knew what he was doing, but after reassembly, no start. Informed me he was having priming issues. A week later, informed me there was an error code on #1 injector (one of the clips must have been broken by someone else.) Somehow cleared that problem without replacement (Hmmmm.) After another week, had some actual diesel techs from a Cat shop bring over some gear and they made the determination that the HPOP had failed. I saw the truck in various stages of disassembly, and noted that the mechanic he had actually turning wrenches on it was not exactly being careful with the fluids and debris he was letting loose while doing the EGR cooler/valve replacement. My question is, could allowing contaminants into the top of the HPOP caused this failure, or is it as he's trying to convince me, merely a coincidence? Truck was running fine other than puffing white smoke when I brought it in... . Any expert opinions?

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Old 02-10-2010, 09:21 AM
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Doing the EGR cooler repair does not need to open the HPOP. If he did open it up, he doesn't know what he's doing in there. If he did not open it, then it's a coincidence.
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Old 02-10-2010, 09:29 AM
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Fuel and oil system dont involve the EGR delete. It is possible that maybe your HG's are in a degree of failure allowing coolant into the oil and some of that making its way to the HPOP??? Maybe? Maybe not. Check your oil and coolant - see if there is any mixing going on. Black deposits in collant resevoir or chocolate milk consistency in oil.

However if air did get into the system - it takes forever and 1/4 tank of fuel to re-prime our trucks.

For the record, when I had all my work done - studs, hg's, full EGR delete - at the assembly and first start my truck would not start and found the IPR to have gone bad and cylinder #4 had failed. Replaced those 2 (along with some other work) and the truck has been running wonderful ever since.

To say the HPOP failed as a result of the EGR delete - this is highly unlikely. However - the HPOP could have been on its way out and simply by happenstance went with the other work being done.

Where do you live?
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Old 02-10-2010, 10:07 AM
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Florida. Little late now, but it's clear this guy didn't know his diesels, let alone the 6.0.
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Old 02-18-2010, 04:28 PM
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We had similar problem in our shop and it turned out to be the IPR valve being clogged. Replaced and fired.
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Old 05-22-2011, 03:53 PM
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6.0

I've changed an EGR cooler on a 6.0, did they take the oil cooler out, if not there's a screen under the oil filter housing with the oil cooler that may have failed. Which will let debree into the hpop pressure regulator causing a no start. You should check it and replace the pre screen, and the screen on the end of the regulator plus clean and blow everything out. It worked for me.
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