F 450 2WD Super Duty V8-6.0L DSL Turbo VIN P (2006)
EGR Valve: Customer Interest
Emissions - Low Power/Smoke/EGR DTC's Set
TSB 08-26-12
01/05/09
6.0L - COKING DEPOSITS DIAGNOSTIC - EGR DTCS
P0401, P0402, P0404, P1335
FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
2004-2009 E-350, E-450, E-550
This article supersedes TSBs 08-2-7 and 07-21-9 to update the Service Procedure and Part List.
ISSUE
Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles equipped with a 6.0L engine may exhibit white smoke, black
smoke, lacks power, exhaust odor, surges and/or exhaust gas recirculation (EGR) diagnostic trouble codes (DTCs) P0401, P0402, P0404, and/or P1335
as a result of excessive coking deposits un-combusted or incompletely combusted hydrocarbons. This procedure should be used only if one or more of
the components listed below have already been identified as having an excessive coking condition.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THE ROOT CAUSE OF THE COKING MUST BE CORRECTED OR THE COKING MAY REOCCUR.
After following normal Powertrain Controls/Emissions Diagnosis (PC/ED) diagnostics, use this procedure to identify the root cause of the excessive
coking condition and if appropriate install an EGR Baffle. Just replacing the component with coking deposits and installing the EGR baffle will not
correct the root cause, and coking will reoccur.
NOTE
SOME 2008 AND ALL 2009 6.0L E-SERIES VEHICLES HAVE THE EGR BAFFLE INSTALLED FROM THE FACTORY.
Service Tips:
Coking deposits are generally un-combusted or incompletely combusted hydrocarbons, commonly sourced from engine oil or diesel fuel. These deposits
can form on system components such as the EGR valve, EGR cooler, exhaust back pressure (EBP) Sensor, EBP tube, intake manifold, turbo charger,
catalytic converter and EGR throttle plate. Visual inspection alone cannot link the sources of coking deposits as either from engine oil or diesel fuel.
Coking deposits can be identified as shiny black grease like sludge, hard flat black solid mass or thin light brown sticky layer.
Un-combusted deposits can be linked to delayed combustion events. Delayed combustion events can be a function of hard to ignite elements like poor
quality fuel, excessive fuel, engine oil or excessive exhaust gas recirculation in the combustion chamber or a delayed injection event like calibration,
wire chafe, injector mechanical issue. Un-combusted fuel is usually evident as fuel scented white exhaust smoke. Un-combusted fuel may create coking
which impairs system functionality eventually leading to black exhaust smoke / poorly combusted fuel.
NOTE
VEHICLE PERFORMANCE ISSUES RELATED TO FUEL QUALITY, MAINTENANCE AND AFTERMARKET MODIFICATIONS ARE
NOT COVERED BY FORD MOTOR COMPANY WARRANTY.
Complete all of the following steps. Devices such as the Catalyst, manifold absolute pressure (MAP) sensor and EBP sensor that fail the PC/ED
pinpoint tests (PPT) must be replaced and not cleaned. Clean the Turbocharger using other applicable TSB's, the intake manifold and EBP tube.
EGR valves that fail the Integrated Diagnostic System (IDS) - EGR Systems Test should be replaced not cleaned.
1.
Follow PC/ED led diagnostics for any specific drivability issues and DTCs.
2.
Check OASIS for open field service actions (FSAs) and complete them before continuing with this procedure.
3.
Validate clean good fuel.
a.
Use PC/ED, Section 4: Diagnostic Subroutines Performance Diagnostic Procedures / Sufficient Clean Fuel.
