If the coolant level is noticebly decreasing and you can not see any drips anywhere, then it is very likely to be the EGR cooler. You mentioned that you were concerned about damaging the new EGR valve, but I would not worry about that. An EGR cooler leak can certainly cause other issues (as serious as hydrolocking the engine), but I do not think it would ruin an EGR valve - at least not very quickly.

Did you look closely in the valley of the engine to make sure the EGR cooler hose is not leaking? I assume that you can not smell antifreeze under the hood?

 

I have tried anything I can think of to see if I can see any leaking....from the top, crawling underneath, etc. You are correct, I do not smell any antifreeze anywhere, and no coolant leaking...I still have the oil drip though (could that be related?)

Is it safe to drive....I don't think the dealership can get me a rental until thursday and this is my wife's kid mover. Just wondering if I can possibly cause any damage driving around with the CEL on?

 

The oil drip is not related.

I would not be comfortable driving it with the possibility of it being an EGR cooler leak.


I will say that my coolant level fluctuates a fair amount. Fluctuating levels can make it hard to say for sure that you have a coolant consumption issue, but ................ When you said you lost 36 ounces, that is quite a bit and is not just a fluctuating level issue.

 

***Update***

Ok guys....drove it to dealership (different one than I have used before, but same one I purchased new EGR valve from last week) I have some history with oil leaks not being fixed from another dealership, so I decided to shake things up.

Took it in this morning, explained to SA what was going on..he actually remembered me, because I had asked him when I bought the valve if it was covered under my 200K Diesel Care 13 Component warranty (which it was not) and the reason I bought it and installed it myself. Got my rental and off I went...he called around 3pm today and said the OIL COOLER burned up causing the EGR COOLER to fail, SO......under warranty they are replacing the oil cooler, egr cooler, egr valve (he is giving my new one back to keep as a spare), doing a coolant flush, and oil change. I bought the Diesel Care Warranty with 99,500 Miles on it, and this repair is being done at 102,340. So to say that I am glad I bought the warranty, is an understatement, and I would certainly recommend the warranty to anybody who can still buy it. By the way..total bill to Ford...around 2700.00.

As soon as I get it back in my driveway I will be installing the DieselSite Coolant Filter Kit that has been sitting on my shelf in my garage for 3 months (was going to wait and install when I did my flush, but since they are doing it..saves me a little time. Is there any problem installing the filter with it full of coolant?

I will keep you guys up to date...I'll be able to pick it up tomorrow afternoon and we will see what happens...Thanks for all your comments!

 

I am not surprised at what they found based on what you had seen. Glad you made the right choice on the warranty (and that the dealership is treating you right)!

 

I did my coolant filter with it full. I lost a little bit when I cut the line on the back of the engine. If you are quick, you will loose only a little. Have some coolant on hand to top it off. I found it easier to lay an couple of towels down when doing that cut to help catching the coolant that does come out.

 

Your making the right choice adding a coolant filter
I would make sure the engine is cold before installing the coolant filter kit. Loosen the degass bottle cap to relieve any pressure or you can just drain the bottle. You will loose some coolant when you cut the heater hose or if you have a couple of vise grips to pinch the hose to keep closed. Just have some 50/50 mix of coolant on hand for you coolant loss.

 

Update? Is it good now?

 

Can someone tell me if the Ford EGR removal tool is worth the money?

How much is it?

Does it work on a E series (with the tiny clearance)?

Or should I jury rig pipe and coat hanger wire?

 

I use a slide hammer with the jaw puller attachment ... unbolt, twist EGR a little, position jaws, and one hit & she'll pop right out.

 

Help! Where is the egr valve? I can clean and replace it if I know where it is.

 

Here are a couple of pictures: The first one you can just see the electrical connection on lower right near oil filter housing. The second is looking over the top of motor.







Also, keep this next link for future use.:

Powerstroke 6.0L Technical Intro Manual

 

Thanks Sean, So can I take it off and clean it? I just started using Lucas fuel treatment. And now it is giving me problems. Is it just excess junk that can be cleaned out?

 

Hey --- I cleaned my first EGR valve.. and it turned out to be a dud EGR valve...

Replaced it with another one... (reconditioned by me).. and worked great.

IMHO --- buy a brand new one from Ford saves a lot of headaches.

 

Thanks, I'll swing by the ford house tomorrow