Jump to content


On-Site Power Stroke Training



Click to buy EGT Sensor Bosses






Your diesel powered guide to the Internet
Fuel Additive Bottle Caps

Fuel Addiditve Caps can cause problems We have heard of this unfortunate and easy to make mistake. You want to take care of your truck and use products that can help promote good fuel quality and system integrity which includes a variety of fuel system additives. Typically these products come in small bottles that have caps containing a coated cardboard disc inside of the cap intended to provide a seal. Apparently these caps are not adequately secured to the cap and may remain stuck to the top of the bottle. If you are not observant and begin pouring your product into the fuel filler of your truck and this seal is stuck to the top of the bottle it may come loose as soon as the liquid begins to flow taking the cap into the fuel tank along with it. So what you say and there is probably all sorts of junk floating about inside you fuel tank? Well, there have been many reports of 2011 and newer Super Duty trucks that have been stopped in their tracks when these seemingly harmless caps get pulled up against the fuel pick up causing a restriction resulting in low fuel pressure and an engine stalling event. When this happens there will be a loud whining sound coming from the fuel supply pump and a low fuel pressure warning on the instrument cluster. This condition will likely be an intermittent and random concern making it very difficult to verify and diagnose therefore you should keep this in mind. And for the vehicle owner reading this, remember to look at your additive bottle before pouring. It just may save you and a technician some headaches.



6.7L EGR Coolers

EGR system concerns historically have plagued all modern diesel engines equipped with them in one way or another. Some failures have been extremely troublesome and even lead to catastrophic engine failures. Despite improvements in design and components one thing continues to be a problem. Carbon. In the 2011 Ford Power Stroke diesel engine EGR cooler cores are known to become restricted which is detected by the engine control software and will result in the Check Engine light being turned on and a DTC (Diagnostic Trouble Code) being set. While it is possible to find an issue with the EGR valve, Bypass valve or a sensor the cause is commonly caused by the cooler being restricted and sometimes completely clogged with carbon. For vehicle owners that have this problem with their trucks we thought it would be cool to show you what the cooler passages look like, both clogged and new cooler cores for comparison. (see image below)


6.7L Power Stroke Diesel engine EGR cooler core comparisionWe see this on random engines that seem to be running perfectly and a range of operating conditions so it is difficult to say what is causing this to happen on some trucks and not others. Mitigating carbon build up on the 6.7L takes the same approach as with it's predecessors. Use good clean fuel, repair any performance issues that can increase the amount of unburned fuel in the exhaust, ensure that your engine's software calibration is up to date, keep engine idling to a minimum and use a quality fuel additive that will boost the cetane rating of your fuel to help promote good ignition and more complete combustion.

As of now there is no known acceptable method of cleaning these EGR coolers and replacement of the core is necessary to correct the condition. This is not a cab off repair by any means and it is pretty straight forward. The only difficulty or possible problem that might occur is the bolts that attach the EGR supply pipe to the right exhaust manifold could seize and break during disassembly. Experienced technicians can usually sense when these bolts are going to be a problem and use methods to finesse the bolts loose but even then it can be a losing battle. The broken fasteners can sometimes be extracted but usually require drilling out with a thread repair insert required.



About DTS Membership

THE DTS FORUMS ARE NOT OPEN TO THE GENERAL PUBLIC. The DTS Forums are for Ford dealer and Ford Corporate employees and International dealer employees ONLY! While the web site is open to the general public, the forums are restricted to the use of Ford and International service technicians, dealer personnel and manufacturing employees array(Ford Motor Company or International and their suppliers) All Forum registrations are screened and are subject to approval before any account is active. You may be contacted for additional information or clarification. Yes, we are serious. If you cannot be responsible enough to provide this simple information that is required to validate who you are your registration cannot be verified and it will be declined. We don't think that it is too much to ask.

Did You Know?
In 1999 Ford introduced an intercooler for the 7.3 DIT engine. The intercooler was put into production on the Ford trucks because there was a change in the turbo. The compressor wheel was larger and the change to a bigger turbo brought more boost and higher exhaust gas temperatures. The new wastegated turbo was capable of maximum boost pressures of 28 psi.




Test Your Power Stroke Knowledge

Think you are a Power Stroke Guru? Have a little time to kill? Try taking our quizzes found in the Inside DTS section of the site. Quiz topics include several Power Stroke diesel engines, basic diesel theory, common acronyms and the popular and challenging DTS Mechanical Aptitude test covering various principals related to the automotive industry.

Hint: Many of the answers are found throughout the DTS website including the Coffee Table Books. Good luck!