6 Liter Powerstroke

The 6 liter powerstroke engine was first introduced in the Ford truck and van lines in June of 2003.  The trucks that carried those engines include the F-250, F-350, F-450, F-550, and F-650, as well as the Econoline Vans and the Excursion SUV (sport utility vehicle). The 6 liter power stroke engine is produced by Navistar International (formerly International Harvester) for Ford, and has gone through several versions.  

6 Liter Ford Powerstroke

The 6 liter powerstroke was designed and introduced by Ford specifically to comply with new emissions regulations passed by the U.S. Congress.  Unfortunately, neither Ford nor Navistar was able to do enough testing and design work on the 6 liter powerstroke engine.  As a result, these engines had tremendously bad failure rates, including hundreds of full under-warranty engine replacements and truck repurchases, as well as a large number of smaller problems.  

6 Liter Powerstroke Exhaust

The EGR (exhaust gas recirculation) valve on the 6 liter powerstroke is a major problem on the early 6 liter powerstroke engines, particularly the 2003 and 2004 models.  Carbon buildup, also known as coking, in the EGR system has caused many problems with the 6 liter powerstroke, including and up to engine failure.  Regular checking and cleaning of the EGR valve is pretty crucial to keeping the 6 liter powerstroke engine running and in good condition.  At one point Ford did not recommend cleaning the EGR valve, but simply replacing it if it was more than 50% clogged.  

6 Liter Ford Powerstroke Turbo

As time passed the Ford recommendation regarding the EGR valve on the 6 liter powerstroke engine changed.  Ford's recommendation began to include cleaning the valve.  Steps to cleaning the EGR valve on the 6 liter powerstroke include manually scraping off carbon deposits with a pick or small screwdriver, followed by brushing off the remaining deposits with a stiff nylon brush.  Cleaning chemicals can be used, but you must exercise great caution when using chemicals, because the actuator and seals inside the valve on the 6 liter powerstroke are extremely prone to damage from chemicals.

6 Liter Turbo Diesel Powerstroke

Another issue with the 6 liter powerstroke engine is the variable-geometry turbocharger, also called the VGT.  This type of turbocharger does allow for a diesel engine to accelerate more quickly, much like a gas-powered vehicle.  However, the earlier versions of the 6 liter powerstroke often had problems with the VGT (variable-geometry turbocharger).  

6 Liter Ford Turbo Diesel

The most common problem on the 6 liter powerstroke turbo is with the solenoid on the actuator.  The actuator opens and closes the vanes of the VGT.  It opens and closes according to the instructions it receives from the computer on the 6 liter powerstroke engine.  However, if the solenoid for the actuator on the 6 liter power stroke is not functioning properly, the vanes will not adjust correctly, resulting in loss of power and other engine problems.