Postby lighthammer » October 3rd, 2010, 12:04 pm
nick009 - I just found out that a common problem with Ford Diesels, esp. with the Powerstroke diesels in the US can be the EGR cooler. It sits downstream from the oil-cooler and receives coolant from the output end of the oil-cooler.
Sometimes the EGR's coolant intake can get clogged up with debris from within the cooling system. This causes the temps inside the EGR to shoot way up, causing coolant to bubble into the exhaust system instead of returning to the coolant resevoir.
Warning signs to look out for:
- unexplained loss of coolant from your resevoir bottle. After checking the entire radiator & piping system, and ensuring the head gasket isn't cracked or leaking and the block itself is solid, the next most likely source of coolant loss is from the EGR into the exhaust system. This leads to warning sign no. 2....
- White smoke from the tailpipe. This is actually steam, from the water-based coolant leaking & dumping into the exhaust system. Keep an eye on the colour of your exhaust and when the white smoke appears
- Gushing of coolant out of the coolant bottle or from the overflow hose. Might be a sign that the oil cooler's pipe are clogged, or the EGR isn't getting enough coolant hence whatever little coolant is inside the EGR is boiling and releasing steam pockets through the coolant system.
In american ford diesels, this can happen after 50,000 miles. I'm not so sure about the UK and Thailand models, but it stands to reason that this may be a possibility, after all other obvious causes are ruled out.
Problem is that these can all add up: Plugged-up engine oil cooler >>> ruptured EGR cooler >>> overheated engine oil >>> overheated fuel injectors >>> loss of coolant overall >>> blown head gasket >>> $$$ to repair.
If your ranger is still under warranty, it might be prudent to take it to McEarney motors and request to have the entire coolant system inspected, including the oil-cooler & EGR cooler. Usually this will be replaced under waranty, but later on the system may be prone to failure again. AFAIK there are 3rd party solutions for American ford engines like a remote oil-cooler with optional oil-bypass function for the coolant.
Hope this helps, or at least leads you to a proper diagnosis & fix even if it wasn't the EGR at fault.
Keep us updated dude, would like to know the eventual outcome for you.