A gummed up EGR valve is usually caused by long engine runs at idle or low speeds. Also, the EGR valve is often coated with soot and stuck in the open/closed position. This usually appears as white smoke from the exhaust pipe. That leads to cracking of the EGR cooler's coolant passages and leaking coolant into the intake system. These cracks usually result in oil pushing its way into the cooling system and forming high-viscosity coolant due to the mixture with oil. Aluminum tubes that go to the oil cooler have the tendency to crack from temperature changes. The exhaust gas recirculation (EGR) system is sources of the main issues with the 6.0L Power Stroke. In the first place in the list of problems are EGR-related issues: cracked EGR coolers and failed EGR valves. The 6.0L Power Stroke has a poor reputation in terms of reliability and durability. The 6.0L Power Stroke proved to be less reliable than its 7.3L predecessor and was replaced in 2008 by a more powerful, durable, and emissions friendly 6.4L Power Stroke.Ħ.0 Power Stroke Engine Problems and Reliability This quick-spooling turbocharger provides quick throttle response. A charged air goes through an air-to-air intercooler. It utilizes the Garrett GT3782VA turbocharger with electronically controlled and hydraulically actuated vanes and 58mm compressor wheel. The 6.0L engine was the first in Power Stroke family equipped with single variable geometry turbocharger (VGT). The Split-shot HEUI fuel injection system allows the 6.0 PowerStroke to produce higher injection pressures throughout the entire operating range (in-cylinder fuel injection pressure can reach 26,000 psi). The HPOP is located under the HPOP cover and turbocharger at the rear of the engine. The HEUI system consists of the PCM (Powertrain Control Module), IDM (Injector Driver Module), the swash-plate style high-pressure oil pump (HPOP), IPR (Injection Pressure Regulator), and Siemens injectors. The fuel injection timing and fuel pressure are controlled by high-pressure oil and electronics. The 6.0 Power stroke engine features an HEUI (Hydraulically Actuated Electronically Controlled Unit Injection). Each head has an aluminum rocker box mounted to the top. The valves were placed in a "twisted" position helping introduce swirl into the combustion chamber. The cylinder head has two separate intake runners per cylinder. The diameter of the intake valves is 33.8 mm (1.33 in), of exhaust valves - 28.0 mm (1.10 in). Cylinder heads are attached to the block using just four TTY head bolts per cylinder. The engine got cast-iron, high-flow cylinder heads with four valves per cylinder (16 intake valves and 16 exhaust valves 32 valves total). At the rear of the engine, there is the gear train for the crankshaft, camshaft and high-pressure oil pump. Connecting rods are very strong and durable, known to handle 700rwhp and 1,200-1,300 lb-ft of torque. Like the 7.3 diesel, the 6.0 has powdered-metal connecting rods and cast-aluminum pistons. Its oil cooler and the high-pressure oil pump are integrated into the engine block. The 6.0 Power Stroke has a cast-iron cylinder block with a crankcase bed plate (no main caps) for superb bottom-end strength.
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