Doin' some work on a 6.0 Powerstroke
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Doin' some work on a 6.0 Powerstroke

  1. #1
    Wishin I was at the lake! Brian's Avatar
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    Default Doin' some work on a 6.0 Powerstroke

    For anyone who's had trouble with their 6.0 Powerstroke... I understand! Mine's out of warranty now, and I took it to the dealer to have an overheating and coolant puking problem diagnosed. They quoted 2600 bucks to replace a bad EGR cooler (3rd one to fail on this truck). That was really just the start, because normally the EGR cooler takes out the oil cooler and sometimes the turbo, so things could have gotten ugly fast. Said "F this" and decided to fix Ford's problem, hopefully once and for all. Bought a kit from Liberator Performance that includes a new turbo up-pipe that has no EGR passage, a coolant bypass tube to replace the EGR cooler, and a block plate for the intake. Found a great deal on a new oil cooler on Ebay for less than half what Ford would charge. Bought new water pump, hoses and belt for maintenance purposes while I was in there. Also added a new larger intercooler, coolant filter setup, higher efficiency radiator, and upgraded fuel line fittings and pressure regulator to keep the injectors happy. Here are a few pics of the mess.

    What your 6.0 looks like underneath all that crap with the intake removed. The oil cooler and filter base are still installed:



    Closeup of the modified up-pipe that feeds the turbo. Important mod - heat shield on the y-pipe has been trimmed to allow access to the bolts from the top. They're a real bitch to get to from the bottom unless you have a lift:



    Intake manifold with POS EGR cooler still installed:



    Bottom of intake with bypass tube and block plate installed:



    New toy, nice part from Spearco (Turbonetics):



    It's bigger:



    Ever wonder what the inside of a VGT turbo looks like? Dirty:



    Clean:



    Vanes open:



    Vanes closed:



    Lot of work, but learned a LOT. Bought a real Ford shop manual before I started - 200 bucks but worth it. Probably would not have had the courage to start this job without it. Saved lots of cursing and broken sh_t! Truck seems to be running again, drove it to work today. Real test will be next time the boat is hooked up and we're headed up a big hill...
    Last edited by Brian; 09-09-2008 at 07:53 PM.

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  3. #2
    Punk in Drublic Tiggle - Bitties's Avatar
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    Great post Brian. Thanks for the detail and pics! I'm outta warranty in about 20K miles and will most definately look into the EGR abortion as it's really the only thing (knock on wood) that's failed us.

    Good luck on the boat pull and keep us updated!
    dave
    Originally Posted by bocco
    "One more thing. Boobs are like boat motors. I never heard a woman say she wished she had gone smaller"

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    HOT SAUCE HERE
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    Great post and I'm pretty impressed I didn't hear any profanity from the other side of Phoenix -- sounds like a job well done I'm going this Sunday to Pleasant to do a 'test ride' on the DCB...you never know what could happen

    Roln 20s

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  6. #4
    Wishin I was at the lake! Brian's Avatar
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    Quote Originally Posted by roln20s View Post
    Great post and I'm pretty impressed I didn't hear any profanity from the other side of Phoenix -- sounds like a job well done I'm going this Sunday to Pleasant to do a 'test ride' on the DCB...you never know what could happen

    Roln 20s
    Well the neighbors *might* have heard a little something if they were listening close enough once or twice!

    Not sure whether to wish you good luck or bad luck on Sunday... Well at least you know you always have a ride in the old sled if you can lower your standards enough to roll in a Magic!

    Hey, if he needs more speed, point him my way... He could save some coin and pick up a couple mph!

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    Member 454Carribean's Avatar
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    I think i read somewhere that the stock 6.0 intercoller is bigger/more effecient than the stock 7.3 intercoller and will swap over. You might be able to sell it to someone to offset your costs slightly.(?)

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    Wishin I was at the lake! Brian's Avatar
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    Thumbs up

    Good idea on the cooler, think I'll clean it up and post it over on some of the diesel sites, or maybe ebay. The stock ones do tend to blow the plastic tanks if you push up the boost, surely someone would be looking for a cheap replacement.

  9. #7
    Wishin I was at the lake! Brian's Avatar
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    Pretty interesting fuel system on these motors. Doesn't use a high pressure mechanical injection pump like the older Cummins or a common rail like the newer ones. Fuel is fed into passages in the cylinder heads at about 65 psi by a regular EFI pump, but with two filters, water separator, and fuel heater circuit. High pressure oil (from the gear driven pump located under the cover in the rear of the valley, visible in the first pic) is fed into separate passages at about 4000 psi. The injectors take the fuel in from the head and run it through an intensifier piston that's driven by the high pressure oil and cranks it up another 7.1 times for a total injection pressure of 28000+ psi! Injector timing and pulse width is controlled electrically by the computer. Guess that's why injectors on these motors are so damn expensive! Or, at least that's my understanding of it, could be off a little of course. Definitely a different world than the gas motors I'm more used to dealing with in the boats.

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