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.
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