ktmlew Posted June 8, 2017 Share Posted June 8, 2017 Truck was brought in with customer thinking needed some injectors. CMDTC P0341-404-405-1335. Had a miss under load that cleared up when warm. #1 injector IS showing some stiction but I wanted to fix the EGR codes first. Oddly enough it would pass the EGR test with flying colors but fail KOER test. Finally pulled EGR and it was plugged solid with carbon. Spent couple hours scraping and vacuuming carbon out. Forgot about just starting it up and blowing the shit out. DOH! Some of it was black/hard--some soft, but all black. Just found out this afternoon he's been adding a gallon of coolant about every 3 months. New radiator and coolant bottle/cap. I replaced EGR with AM and it failed EGR test! Got a Ford part. Passes EGR test but still kicks P0404/P1408 in KOER. also ran BG EGR & intake cleaner process. Really didn't seem to do much IMO. So? Noticed when changing EGR's the lower part of intake is wet. Now I'm thinking EGR cooler is leaking. Going to pull EGR, jack rear end up, pressure test cooling system. I've been out of the PS business for about 10 years so waaaaaaaaaaaay behind. But DO have IDS and access to Ford site. So. Why does it keep kicking the P0404/P1408? Turbo vanes carboned up? We will do the injector/injectors but would like to FIX the truck. Our shop will "fix" the truck (EGR) if you know what i mean... Quote Link to comment Share on other sites More sharing options...
ktmlew Posted June 8, 2017 Author Share Posted June 8, 2017 Got it. Had to resize. Bowl pic is after i had been cleaned EGR for a few minutes. I'll get a picture in the monrning showing how wet it is in bottom. But how does this valve pass EGR test? Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted June 9, 2017 Share Posted June 9, 2017 Jeez that one is really coked up. That's a canidate for a total intake removal and cleaning plus addressing the EGR cooler while you're in there. Don't forget the oil cooler and cleaning the turbo too. I have seen many EGR cooler failures accompanied with a badly rusted up turbo Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted June 9, 2017 Share Posted June 9, 2017 Looks like that EGR cooler has been leaking for a while. The hard crust is the evidence of coolant build up. If clogged, cleaning that port in the intake will prove difficult and time consuming. I either use a local radiator shop that will hot tank them or I replaces them. Quote Link to comment Share on other sites More sharing options...
ktmlew Posted June 9, 2017 Author Share Posted June 9, 2017 So far I now have six people saying cooler leaking. Now to convince boss and customer. Thanks guys. Quote Link to comment Share on other sites More sharing options...
Keith Browning Posted June 9, 2017 Share Posted June 9, 2017 So far I now have six people saying cooler leaking. Now to convince boss and customer. Thanks guys. What you need to understand is that when EGR coolers fail in a big way it is common for the EGT valve to get a steam cleaning and will usually look almost brand new if subjected to that condition long enough. In this case you need to remove a chunk of that carbon and break it up - looking for light streaks of gray or noticeably lighter colored carbon that is typically quite hard and crumbly. You will find that when an EGR cooler develops a very minor leak and passes the coolant in small amounts. Look for the DTS article on "EGR Marbles" for a complete write up and pictures on this. Quote Link to comment Share on other sites More sharing options...
ktmlew Posted June 9, 2017 Author Share Posted June 9, 2017 Wet bowl without pressure. pulled EGR first thing this morning. Picture doesn't really show drops of coolant. 1 Quote Link to comment Share on other sites More sharing options...
ktmlew Posted June 9, 2017 Author Share Posted June 9, 2017 Other tech has it apart. Cooler was seeping at up-pipe end. About 1/3 plugged with carbon too. They will have cooler welded shut. Deletes are done around here all the time. Quote Link to comment Share on other sites More sharing options...
ktmlew Posted June 11, 2017 Author Share Posted June 11, 2017 EGR Flow = IAT2 sees ^100* increase when EGR valve commanded open at cruise speed. Quote Link to comment Share on other sites More sharing options...
forddieseldoctor Posted June 12, 2017 Share Posted June 12, 2017 EGR Flow = IAT2 sees ^100* increase when EGR valve commanded open at cruise speed. Iat2 may go up but the combustion temps go down. 1 Quote Link to comment Share on other sites More sharing options...
forddieseldoctor Posted June 16, 2017 Share Posted June 16, 2017 I got a really dumb question.... if someone welds shut the ends of a ruptured egr cooler won't it continue to leak carbon into the cooling system? Quote Link to comment Share on other sites More sharing options...
RyanG Posted June 16, 2017 Share Posted June 16, 2017 I would think so. If coolant can get into the exhaust side, it can circulate back through in to the cooling system. Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted June 16, 2017 Share Posted June 16, 2017 If the welds are sealed up it won't leak carbon but any remaining carbon in the core could get into the cooling system Quote Link to comment Share on other sites More sharing options...
forddieseldoctor Posted June 16, 2017 Share Posted June 16, 2017 If the welds are sealed up it won't leak carbon but any remaining carbon in the core could get into the cooling system That's what I meant. You just made it sound better. Quote Link to comment Share on other sites More sharing options...
Matt Saunoras Posted June 17, 2017 Share Posted June 17, 2017 Quote Link to comment Share on other sites More sharing options...
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