6.0 Dead After EGR Cooler Repair
 

Have a 2005 F250 6.0 PSD that started blowing white smoke. EGR cooler failed. Had a mechanic that said he knew what he was doing, but after reassembly, no start. Informed me he was having priming issues. A week later, informed me there was an error code on #1 injector (one of the clips must have been broken by someone else.) Somehow cleared that problem without replacement (Hmmmm.) After another week, had some actual diesel techs from a Cat shop bring over some gear and they made the determination that the HPOP had failed. I saw the truck in various stages of disassembly, and noted that the mechanic he had actually turning wrenches on it was not exactly being careful with the fluids and debris he was letting loose while doing the EGR cooler/valve replacement. My question is, could allowing contaminants into the top of the HPOP caused this failure, or is it as he's trying to convince me, merely a coincidence? Truck was running fine other than puffing white smoke when I brought it in... . Any expert opinions? :humm:

How did they determine that the EGR cooler had failed? When we remove the cooler we pressure test them. Next, puffing would indicate an issue with a single cylinder. Your mechanic should be able to run computer tests to verify that everything is correct. Before even firing the truck off we like to check codes and buzz the injectors just to be sure everything is dialed before hitting the key.

Now, as for junk getting into the oil system, absolutely that could take out a HPOP.

If your EGR cooler was in fact bad, then the mechanic should have changed the oil cooler as well. Did he?

He did not replace the oil cooler... .

No idea if he checked either?

He just claims he replaced the EGR cooler. No idea if he did any pressure testing.

Well, I wish I could be more help, but without knowing what he did or why I really am at a loss. Long story short I don't think that proper diagnostics were performed and it sounds like proper repair procedures were not followed.

Well, thanks. Simply looks like a lesson learned, fast, cheap, good... pick two only.