Combustion gases in the coolant - Diesel Forum - TheDieselStop.com
Transit Diesel Technical discussion of Ford's new Transit Van powered by a diesel engine.

 
LinkBack Thread Tools Display Modes
post #1 of 13 (permalink) Old 04-21-2016, 09:34 AM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
Combustion gases in the coolant

This old girl got hot yesterday and when I got it in here and cooled down enough to add coolant (Two gallons), I had the cap off and with the engine running, I noticed what I thought was burping of air, but the coolant level wasn't dropping and it just continued to burp.

I got a bad feeling and got out the magic block tester with the blue fluid that will turn yellow as combustion gases pass through it. Sure enough, it turned yellow in about 30 seconds or less.

Crap.

So now I think I'll dig out my sailor dictionary and pull the EGR valve, looking for coolant.

The EGR cooler is mounted to the back of the head. Not a big deal if they had provided a doghouse to remove, not so much fun without it.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
TDIDog is offline  
Sponsored Links
Advertisement
 
post #2 of 13 (permalink) Old 04-21-2016, 10:01 AM
Lifetime Supporting Member
Lifetime Supporting Member
 
Join Date: Dec 2013
Location: Maryland
Posts: 7,913
My Photos: (1)
Feedback Score: 0 reviews
Sorry if it's your, cool if not. Get pictures if you can.
Maryland dieselnick is offline  
post #3 of 13 (permalink) Old 04-25-2016, 12:59 PM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
I got it hot and bubbling exhaust gasses and pinched off the two hoses for the EGR cooler. I ran it up to 1800 RPM and no bubbles. Unclamped the hoses and back to bubbles. It looks like the EGR cooler will come out on the drivers side, from below. OR, once I get the EGR valve out, it may come out the top. Either way, it's gotta cool down first.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
TDIDog is offline  
Sponsored Links
Advertisement
 
post #4 of 13 (permalink) Old 04-25-2016, 10:05 PM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
I got that SOB out. Lots of working from top then bottom, then top then bottom. Wash, rinse, repeat. Once it was unbolted, it came out the bottom on the driver's side but the EGR valve came out the top. It wasn't nearly as bad as I figured it was going to be. When I loosened the Vclamp at the exhaust manifold, coolant poured out so I was 100% sure I was on the right path. Getting it out was messy with coolant running down hour arm with every move and is best done by someone else.
TDIDog is offline  
post #5 of 13 (permalink) Old 04-25-2016, 10:06 PM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
Pictures will follow.
TDIDog is offline  
post #6 of 13 (permalink) Old 04-25-2016, 10:45 PM
Lifetime Supporting Member
Lifetime Supporting Member
 
Join Date: Dec 2013
Location: Maryland
Posts: 7,913
My Photos: (1)
Feedback Score: 0 reviews
Awww man, coolant showers stink
Maryland dieselnick is offline  
post #7 of 13 (permalink) Old 04-26-2016, 09:29 AM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
Descriptions precede pictures.

The EGR valve is in this picture. Really, it is. It has the grey top way back there behind the wiring harness.



Way back in there is the other side of the cooler. From the blue washer fluid cap, go straight up and at the back of the head, you will see a black blob. That is the cooler. I took off the fresh air intake, but I'm not sure I needed to. Yes, it helped, but there isn't much to do on this side and in order to get it off, you have to remove the rain tray and if you take that off, where will you put your nuts?



This is the valve from the bottom. The oil cooler is at bottom center and I pinched off that hose and the hose that is connected to the tube to the right of that black, plastic tube in the picture. This hose comes from the block.



Here is a the service position for all of the hoses and wires and tubes. There are three wire connections back there: EGR valve, Cam sensor and Rail pressure sensor. The harness is zip-tied to two plastic channels. I removed one and removed part of the harness from the other. You can also see the EGR Temperature #2 sensor in this picture. It's the long, thin metal thing with the wires on it to the left of the brake booster. I think that you could pull that and look for coolant or see if it's clean. The one plastic channel that I removed has one bolt on it and one retainer on the horizontal part. remove the bolt and you can slide the channel off of the retainer by pushing it to your left.



This is a view of the exhaust side with the heat shield removed and the vacuum line for the diverter valve moved. Three bolts on the heat shield, the vacuum line and the V Clamp is all that is needed on this side. The bolt for the clamp snapped as I was removing it. No rust, so I don't know why it broke. I suggest ordering it.



This is what I saw when I removed the clamp: Coolant running out. Definitely cooler leaking.



Between the valve and the intake manifold you can see one of the nuts holding the pipe to the valve. Mostly this was all done by Braille, but occasionally you can see things. you can also see the grey connection end of the cam sensor.



EGR valve. Apparently they just used this as a convenient place to support the hose rather than it being cooled.



There she is. Notice how clean it is on the right (outlet) side. There are just two bolts holding it to the head and both of them are relatively easy access from your right. There is a gasket on each end as well as the one on the bottom of the EGR valve. Ford says the cooler comes with the ones mounted to it, but be sure to order the one for the valve as well. And the clamp.



All told, it should be a 2-3 hour job to get it out. I spent most of the day, but I was also doing alot of other stuff as well, so it's hard to tell exactly how much time I spent on it.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.

Last edited by TDIDog; 04-26-2016 at 09:41 AM.
TDIDog is offline  
post #8 of 13 (permalink) Old 05-02-2016, 07:22 PM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
I talked to Bullet Proof Diesel And they were interested in this EGR Cooler. I was waiting for him to get back to me, but he hadn't even after I sent a reminder Email. Hmmm. Guess they aren't interested.

Today they call me again because they do want this cooler. The reason he was reminded of our conversation is that someone else had called to talk to them about the failed EGR cooler on their 100,000 miles Transit.

They sent me a shipping label, so all I need to do is drop it off with FedEx. He promised me pictures once they get it apart. I will ask if they will allow me to share.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
TDIDog is offline  
post #9 of 13 (permalink) Old 05-02-2016, 08:38 PM
Lifetime Supporting Member
Lifetime Supporting Member
 
Join Date: Dec 2013
Location: Maryland
Posts: 7,913
My Photos: (1)
Feedback Score: 0 reviews
That's cool, thank you for taking the time to put tools down, pick up camera and write instructions.
Maryland dieselnick is offline  
post #10 of 13 (permalink) Old 05-03-2016, 08:16 AM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
I just noticed that I said that the cooler comes with the gaskets mounted to it, but that's wrong. It only comes with the gasket on the exhaust manifold end. So, you will need the two gaskets for the EGR valve and the exhaust manifold V clamp as well as the cooler. Parts should run you $250-$275.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
TDIDog is offline  
post #11 of 13 (permalink) Old 05-05-2016, 06:29 PM
Member
 
Join Date: Feb 2014
Posts: 41
My Photos: (0)
Feedback Score: 0 reviews
The guys at Bullet Proof are top notch, we chase/race in Baja in the desert southwest, and they really are Bullet Proof.
There are times when race wins, even lives depend on the reliability of your diesel, we need 100%, 100% of the time.

2003 E-350 7.3PSD 95k or so
To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.
Coolerking is offline  
post #12 of 13 (permalink) Old 06-05-2016, 09:58 AM
Junior Member
 
Join Date: Jun 2016
Posts: 2
My Photos: (0)
Feedback Score: 0 reviews
I wonder if excessive pressure was built up in the radiator as the egr leaked?
Fuel squeezer is offline  
post #13 of 13 (permalink) Old 06-06-2016, 09:11 AM Thread Starter
Senior Member
 
Join Date: Jun 2011
Location: Bend, Or.
Posts: 532
My Photos: (4)
Feedback Score: 0 reviews
The cap should have protected the radiator by dumping at it's set pressure. I will keep an eye on the radiator though.

2, 2007.5 LMM C5500 passenger buses each travelling 100,000 highway miles a year, as of December 2014, each over 700,000 miles.
1, 2006 C5500 passenger bus, with a reman engine at 425,024 miles on 28 Sep 2014.
1, 2013 Freightliner M2 chassis/Cummins 6.7 ISB passenger bus travelling 100000 mountain miles per year.
2, 2010 Ford F650 buses with Cummins engines, each at about 300,000 miles.
1, 2015 Ford Transit 11 passenger wagon with the Powerstroke 5 cyl engine traveling about 125,000 miles per year.
The bane of my existence: A 2006 Sprinter.
And a bunch of stupid minivans.
TDIDog is offline  
Sponsored Links
Advertisement
 
Reply

  Diesel Forum - TheDieselStop.com > Ford Diesels > Transit Diesel

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Diesel Forum - TheDieselStop.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in











Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome