Cust. Convinced its an EGR Cooler

BLittle500 · September 21, 2009

Guy comes in with an '06 F250, Says its blowing white smoke, had it somewhere else and they said it needs an EGR cooler. I get it to check out, go driving, it only puffs some white smoke when on hard accel. It doesnt dump out like I've seen in the past with EGR coolers. I get it in to test it, it's still hot so I pull the EGR valve for shits and giggles. It's coked up a little, but nothing much, AND it's dry. The truck cools down and I do the "on vehichle EGR cooler test". It holds 20/in vacuum for 15 mins, then I let it go for another 5, and it doesnt change. Any possibility that this thing needs an EGR cooler? The TSB doesnt have me doing anything else with the EGR cooler after it passes the on truck test.

GregKneupper · September 21, 2009

Has the guy mentioned anything about having to add coolant? I have had bad egr coolers hold a vacuum. What is you ect eot spread? Does the egr pass the egr system test? I have also seen turbochargers blow white smoke on acceleration from a stop.

sam · September 21, 2009

Also if the IAT 2 sensor has carbon on it, it will add more fuel and cause a white smoke problem aswell.....Thinking that the temp is cooler than it really is..... I always remove it and clean it, most of them are completly pluged up....

BLittle500 · September 21, 2009

Nothing about adding coolant. EOT/ECT is only about 4-5 degree split on the 2 road tests that I was watching them. EGR system does pass the EGR test. Checked for excess oil in the CAC tubes, and they were clean.

I pulled the IAT 2 sensor, it had build up, cleaned it off but made no change.

Ford is saying that the white smoke may be coming from this truck not having a cat. converter, any thoughts on that?

Thanks again guys,

Brandon

Bruce Amacker · September 21, 2009

What's MFDES at a hot idle? I like to see under 14mg on a 6.0. higher than that indicates fuel starvation or poorly atomizing injectors. Is the power balance test even? I'd fill the secondary FF with Stanadyne or PM17a and see if it made a difference, indicating poor fuel quality (low cetane) or bad injectors. White smoke is commonly misfire from fuel starvation (probably not your problem) or other reasons.

Not having a cat could definitely affect this, as it's job is to remove PM and unburned fuel from the exhaust stream. Does the cust say the problem is new or recent? Any history?

Does it run perfect?

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BLittle500 · September 22, 2009

Guy just bought the truck, took it to another (non dealership) shop for the white smoke. They told him the EGR cooler was cooked, and he brought it in for warranty work. This truck runs flawless, it just seems like on "tip in" it rolls the white smoke, but only for a little bit.

Bruce, when your looking for the MFDES @ <14mg, is that .14mg?

Power balance is even, and picking off the injectors seems to affect each cyl equally.

Thanks again guys,

Brandon

Bruce Amacker · September 22, 2009

Yes, brain slip, .14mg......

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BLittle500 · September 22, 2009

Just checking Bruce, I didnt know and though maybe I was WAY off, but this truck is okay.

GregKneupper · September 22, 2009

I have replaced a few turbo chargers for that exact concern. Although without a cat converter that could be your issue as well. If you feel confident the cooler is not leaking I would look else where. Also since your ect eot spread is no more than 15 degrees more than likely your cooler is ok.

BLittle500 · September 23, 2009

Truck came back just as I was leaving today. Cust is not happy with the smoke, wants it fixed.

I ran the EGR test on it quick, it did pop out of MAP spec like 3 times durring the 2nd running test, but it did not fail it. The valve was hanging low on the position test, but again did not fail. Maybe I should just try a valve in this thing. Now it has now power from a stop, then all at once comes in. Ran a boost test on it as well, only 1.9psi with a hot engine.

Keith Browning · September 23, 2009

Yeah I had a bad EGR on a bus not too long ago. Never set a code. Ford bounced the claim despite my description of what the valve was doing and the driveability concern it caused because there was no DTC. If you put an EGR in it make sure you have a DTC documented on the RO. I don't condone lying but you want to get paid... especially if it fixes the truck.

gasgasman · September 24, 2009

Could be gas in the fuel.

Seen that a few times.

BLittle500 · September 25, 2009

EGR Valve was no help, although now it passes the tests with flying colors.

I pulled the secondary filter to check the fuel. Looked/smelled like diesel, didnt seem to have any gas in it. Smelled the fuel through the filler neck as well, didnt seem to smell like gas.

Thing thing is a dog off the line, could a sticking turbo cause white smoke?

LARRY BRUDZYNSKI · September 25, 2009

Have you taken a fuel sample? Possible contamination? Delam? What fuel is he using? How long has it been since it got a oil change and what kind of oil was used?

BLittle500 · September 25, 2009

VVT Test from this truck, I dont see anything out of the ordinary, maybe someone else does.

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BLittle500 · October 1, 2009

Ugh, the saga continues. Turns out this pig only had 37PSI on the flow tester, put filters in and got 39PSI out of it. Did the tests, came up with a pump, still only 41PSI. Put a regulator on it and brought the pressure up where it should be. Still smoked. Hotline had me "super heat" the EGR cooler by holding the valve open and running the truck at 1200RPM for 15 mins, then re-test on truck, passed once again. Now they had me "put one bank of injectors in, if problem gets better, replace other bank. If problem does not get better the problem injector may have been missed, replace other bank". So they have me throwing 8 injectors at this thing, guess we'll see how that works out tomorrow.