6.0 EGR COOLER

Has anybody had a problem with the egr cooler leaking on a 6.0? I work for my granddad at his garage and we work on gas motors mainly. We usually just do normal maintence on diesel truck and stuff but never tear motors apart until a friend of the family had a water leak on their 6.0 psd. It turned out to be the egr cooler and it took me a few days to get it apart and back together and didnt know if this was a common problem for the 6.0 psd.  

Its a very common problem.  We now make an EGR Cooler Upgrade Kit to help with these.  We have replaced numberous coolers in our own shop.  After replacing the old cooler with our upgrade - problem solved.  You can find them by googling 'egr cooler upgrade kit'.

Good question, by the way.  Well done!

Gene  

What is the pourpose of the EGr and what other engines are they found on?  

Exhaust Gas Reculation Valve just about every car or truck,  purpose emissions  they take exhaust gas and put it back through the intake  

Thanks  

Just to add to this, the idea behind re-introducing exhaust gas into the intake tract is to cool the combustion chamber and reduce oxides of nitrogen.

Cooling the combustion chamber with exhaust gas sounds backward, but the exhaust gas is inert and occupies space that would normally be taken up by air and fuel in a gas engine, or in a diesel, just air. This process cools the combustion event as there is less volume to fire, so to speak.

Hope that makes sense.  

It would seem to me that the air coming from the turbo running through an intercooler would be alot cooler than burnt exhaust gasses running back through the combustion chamber. I always thought that once the combustion process was finished, that to run it back through the combustion chamber again was just hurting the performance of the engine. I dont understand why you would want to run burnt exhaust gasses back through, instead of fresh air that would help burn the fuel, and cool the egt's. I know this only has to do with emissions, but it still doesn't make any sense to me.  

linmup:
It would seem to me that the air coming from the turbo running through an intercooler would be alot cooler than burnt exhaust gasses running back through the combustion chamber. I always thought that once the combustion process was finished, that to run it back through the combustion chamber again was just hurting the performance of the engine. I dont understand why you would want to run burnt exhaust gasses back through, instead of fresh air that would help burn the fuel, and cool the egt's. I know this only has to do with emissions, but it still doesn't make any sense to me.

Exhaust gas cools the combustion event because it is inert. In other words, it's already burned and can't burn again. When the fuel hits the compressed air in the cylinder and burns on the power stroke, it creates heat. Along with the heat, it creates emissions (oxides of nitrogen being the one EGR is trying to reduce).

Now, look at it this way: an engine with no EGR has 100% air in the cylinder awaiting combustion from the injector/nozzle spray. That will create a corresponding amount of heat.

Now take an engine with EGR: Let's say for conversation's sake that the cylinder has 80% air and 20% exhaust gas. Remember the exhaust gas is inert and will not burn again. When the injector fires the cylinder on the power stroke, there is 20% less heat production from the power stroke compared to the power stroke with no EGR. The reason there is less heat is there is less fresh volume available to burn.


Now, that 20% heat reduction figure is for conversation's sake. I have no idea what percentage of EGR occupies the cylinder at various EGR valve positions and what temperature reduction occurs as a result.

Does that make any sense?  

yes it does, thanks for explaining that.  

yes it does, thanks for explaining that.  

Thanks for the info  

linmup:
It would seem to me that the air coming from the turbo running through an intercooler would be alot cooler than burnt exhaust gasses running back through the combustion chamber. I always thought that once the combustion process was finished, that to run it back through the combustion chamber again was just hurting the performance of the engine. I dont understand why you would want to run burnt exhaust gasses back through, instead of fresh air that would help burn the fuel, and cool the egt's. I know this only has to do with emissions, but it still doesn't make any sense to me.

shookme:
Exhaust gas cools the combustion event because it is inert. In other words, it's already burned and can't burn again. When the fuel hits the compressed air in the cylinder and burns on the power stroke, it creates heat. Along with the heat, it creates emissions (oxides of nitrogen being the one EGR is trying to reduce).

Now, look at it this way: an engine with no EGR has 100% air in the cylinder awaiting combustion from the injector/nozzle spray. That will create a corresponding amount of heat.

Now take an engine with EGR: Let's say for conversation's sake that the cylinder has 80% air and 20% exhaust gas. Remember the exhaust gas is inert and will not burn again. When the injector fires the cylinder on the power stroke, there is 20% less heat production from the power stroke compared to the power stroke with no EGR. The reason there is less heat is there is less fresh volume available to burn.


Now, that 20% heat reduction figure is for conversation's sake. I have no idea what percentage of EGR occupies the cylinder at various EGR valve positions and what temperature reduction occurs as a result.

Does that make any sense?

That makes about as much sense as me staying cool by sucking a fart in
You're going to run more efficient with clean air, hence all the delete companies reporting a drop in egts with a EGR delete installed.  

i just got a headache but good info