If the Oil temperature gets too hot it can cause gaskets and O-rings (in the HPOS) to fail and the lack of coolant flow to the EGR cooler will cause it to fail and can and will cause head gaskets to fail as well. When the Oil cooler is not restricted the coolant temperature and oil temperatures should be within a couple degrees of each other, anything above a 15 degree difference indicates a problem. The sand is left over from the casting process of the engine block and because it was not thoroughly cleaned from the coolant passages before the engine was assembled and it gathers at the most restrictive point which is the Oil cooler. The reason the Oil cooler gets restricted and clogs up is due to silicone sand in the coolant system. There are no warning signs for a clogged or restricted oil cooler but tests can be done to determine if a problem is there waiting to happen. The oil cooler cools the engine oil by heat transfer from / through the engine coolant, kind of like a mini radiator. The Oil cooler is the cause of most the 6.0 Power Stroke engine problems. The EGR Cooler fails because of a clogged or restricted Oil Cooler.Ģ003 model year 6.0 Power Stroke diesel egines have a round EGR cooler, which is less prone to failure than the less efficient square cooler found on 2004 to 2007 model year engines. When soot builds up in the EGR cooler, it can become clogged and the excessive heat can boil coolant in the exchanger.ĭepending on the severity of the failure, the engine can hydro-lock and cause severe engine damage, which includes bent connecting rods. Both EGR cooler and the EGR Valve are prone to failure, the common culprit being soot buildup. When it fails it will cause coolant to enter in to the intake manifold and be burned in the combustion chamber causing a loss of coolant and white smoke from the tail pipe. The EGR Cooler cools the exhaust gas that is recirculated back into intake manifold so that it can be re-burnt for cleaner emissions. The IPR will fail due to debris being passed through it caused by not using a Ford OE oil filter, part number 3C3Z-6731-AA. The HPOS on the 03 to early 04 6.0L Power Stroke engines are a different design and most of the issues are caused by a bad ICP (injection control pressure) sensor, located under the turbo, which fails due to heat, or a failed HPOP (high pressure oil pump) and / or a failed IPR (injection pressure regulator). Symptoms are hard start / no start, loss of power and occur mostly when engine is hot. If you still have the STC fitting on your 05-07 6.0 Power Stroke Engine, it is just a matter of time before it fails. The STC fitting was used in the 05-07 6.0L Power Stroke engines and has a 100% failure rate. Ford has improved the design of the O-rings and has an updated fitting that replaces the STC (snap to connect). Problems with the HPOS are oil leaks (internal to the engine) due to failed/deteriorated O-rings that are caused by excessive oil temperatures (bad oil cooler) and high pressure. The 6.0L Power Stroke fuel injection system operates on oil pressure, very high oil pressure. 1) Ford 6.0L HPOS (High Pressure Oil System) Read our guide on how to bulletproof your 6.0 Powerstroke or the 7 best mods for the 6.0. Note: This article is not to discredit the 6.0, just to address some common issues, which can be resolved, resulting in a much more reliable engine.īelow are the most common problems associated with the 6.0 Power Stroke engine. Some of the early 6.0 Power Stroke engines experienced problems, and it is speculated to have cost Ford millions of dollars in warranty repairs and buy backs. It also uses a 2nd generation (G-2) HEUI (Hydraulic-Electronic Unit Injector) direct injection fuel system.
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