Fulltext TSBs

Technical Service Bulletins

TSB
10-22-9
  • 6.7L – EXHAUST LEAK AT EGR INLET TUBE – POSSIBE MIL ON WITH DTC P0299 OR P132B
Publication Date: November 9, 2010

FORD:
2011 F-250, F-350, F-450, F-550

ISSUE:

Some 2011 F-Super Duty vehicles equipped with a 6.7L diesel engine may exhibit an exhaust leak at the EGR inlet pipe flex joint possibly accompanied by a malfunction indicator lamp (MIL) and diagnostic trouble code (DTC) P0299 or P132B. This concern is caused by a crack in the flex joint which typically results from a loose fastener between the pipe support bracket and the EGR cooler. Exhaust leaks may cause DTCs P0299 and/or P132B. In addition, leaks can result in higher under hood temperatures and may lead to potential damage of the EGR bypass vacuum actuator, EGR bypass vacuum line, RH windshield washer hose, washer nozzle or engine air induction duct.

ACTION:

Follow the Service procedure steps to correct the condition.

SERVICE PROCEDURE

  1. With the engine off, inspect the EGR inlet pipe for soot deposits in and around the braided mesh at the flex joint.
    1. If soot deposits are present, proceed to Step 3.
    2. If no soot deposits are present, proceed to Step 2.
  2. Using EngineEar JSP06608-D located in the Rotunda Technician Tool Program, or equivalent, and with the engine running, listen for an audible exhaust leak at the EGR inlet pipe flex joint and/or sealing gasket areas.
    1. If a leak is evident at the EGR inlet pipe flex joint or sealing gasket areas, proceed to Step 3.
    2. If no leak is evident at the EGR inlet pipe flex joint or sealing gasket areas, do not continue with this article.
  3. Replace the EGR valve inlet tube.
    1. Remove the six (6) bolts and the EGR valve inlet tube.
    2. Discard the two (2) EGR valve inlet tube gaskets, EGR inlet tube and the one (1) bracket fastener. (Location A – Figure 1)


      Figure 1 – Article 10-22-9

    3. Install a new EGR inlet pipe and gaskets, tube support bracket and six (6) bolts.
    4. Reuse five (5) bolts and install one (1) new fastener. (Location A – Figure 1)
    5. Torque bolts in the sequence shown:
      1. Tighten two (2) bolts at EGR inlet pipe to exhaust manifold to 88 lb-in (10 N-m).
      2. Tighten two (2) bolts at EGR inlet pipe to EGR valve housing to 88 lb-in (10 N-m).
    6. Apply Motorcraft®Threadlock 262 to the pipe bracket fastener threads.
    7. Torque bolt to 88 lb-in (10 N-m) + 45 degrees. (Location A – Figure 1)
    8. Tighten the bracket to inlet pipe bolt to 88 lb-in (10 N-m) + 45 degrees. (Location B – Figure 1)
    9. Proceed to Step 4.
  4. Inspect the following areas, visually, for possible damage due to exhaust gas exposure: RH washer hose, washer nozzle, EGR bypass vacuum actuator, EGR bypass vacuum line, and engine air inlet duct. Repair as necessary.

PART NUMBERPART NAME
BC3Z-9E469-ATube – EGR Inlet
BC3Z-9D476-DGasket
BC3Z-9V443-AEGR Bypass Actuator
W503279-S437Bolt (Figure 1 – Location A)
TA-26Motorcraft®Threadlock 262
BC3Z-9E464-EGasket

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATIONDESCRIPTIONTIME
MT102209Use SLTS Operations If Available; Claim Additional Diagnosis Or Labor Performed As Actual TimeActual Time

DEALER CODING

BASIC PART NO.CONDITION CODE
9e46901

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

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