There are many different causes of Ford 6.4 diesel engine failure, from pistons with a large bowl in the middle to a Horizontally-mounted EGR cooler that fails to cool. These can all result in a variety of problems with the engine and need to be repaired or replaced. This article will cover some of the most common problems and how to fix them. We will also cover other causes of Ford 6.4 diesel engine failure.
6.4L pistons have a large bowl in the center
Most Ford 6.4L pistons feature a large bowl in the middle, and the stock design forces fuel to spray into the center of the piston. However, newer pistons feature a re-entrance bowl, ensuring that the fuel burns on initial injection. This design does not increase power or torque, but it does burn fuel cleaner. This is because the fuel injection cycle is longer, and the injector pulse width is widened.
The 6.4L Power Stroke has a long history of engine failures, so replacing a blown piston can be a big job. A new Ford 6.4L piston has a bowl-shaped bowl in the center, which makes the engine easy to maintain. However, the large bowl in the center makes the engine more prone to stalling. For this reason, the 6.4L Power Stroke is notorious for failing, so replacing the piston is vital to maintaining a healthy engine.
Despite the large bowl in the center of the piston, the 6.4L Power Stroke engine can still make impressive numbers, but it will hit a roadblock at around 600rwhp when the factory injection system stalls. Moreover, a Ford 6.4L pistons can check out at 900rwhp, if they are not O-ringed.
Another way to check for cracks is to use a boroscope. A boroscope can help you identify cracks in the injector. These cracks usually appear in the bowl at the three and six o’clock positions. But because the injector’s hole is in the center, the camera cannot see the edges. The cracks are sometimes hidden under soot or diesel fuel.
Horizontally mounted EGR cooler fails
A horizontally mounted EGR cooler on a Ford 6.4 diesel may not work properly. This can be due to several reasons. The cooler may become corroded, sooty, or rusted. It may also be rupturing, leaking coolant into the engine. Most of the time, this failure is associated with a plugged oil cooler. This will restrict the flow of coolant to the EGR cooler. If the cooler fails, the temperature of exhaust gas will be high enough to cause hydro locking.
The problem can also be caused by the expansion bellows that are located on the inlet pipes for the turbocharger. In some cases, the expansion bellows can crack or leak, causing the exhaust to squeak and hiss. Another possible reason is low ICP, caused by aeration of oil dilution. In addition, the PCM and FICM must be updated with the latest calibration to solve this problem. Additionally, a sticking EGR throttle plate can result in air restriction and reduced power.
The EGR cooler on the 6.4L Powerstroke Diesel engine has a problem known as horizontally mounted EGR failure. Many of these failures can be attributed to neglected maintenance or power-adding devices. The problem with the horizontally mounted EGR cooler is that it doesn’t get enough air to the engine. As a result, the EGR is not functioning properly, which can lead to catastrophic failure of the engine.
Leaking fuel injectors in a 6.4L platform can result in major engine damage. The excess fuel entering the cylinder can cause pre-ignition, which can result in catastrophic failure of the piston. In addition, the engine could also experience hydro locking, bending of the connecting rods, or even a complete engine shutdown. Leaking injectors are a common cause of major engine damage, and in many cases, no check engine light is present.
Leaking fuel injectors
If your truck is experiencing rough idle or surging, you may have leaking fuel injectors. There are several possible reasons why your injectors may be leaking. If they aren’t plugged in, they may need to be replaced. You can easily replace them yourself, but you should replace the high-pressure fuel lines before installing the new injectors. Leaking fuel injectors on a Ford 6.4 diesel can be a major problem, so it is important to take the car to a mechanic as soon as possible.
Leaking fuel injectors are a potential safety hazard, and if left untreated, they can cause serious damage to the engine. By following proper maintenance and cleaning techniques, you can restore your leaking injectors to like-new conditions for a fraction of the cost of new ones. Leaking fuel injectors can lead to serious engine problems, such as hydro-lock or oil thinning.
The first sign of leaking fuel injectors is usually noticeable when the engine is cold. This type of problem is difficult to diagnose for an inexperienced diesel mechanic. A cracked Ford 6.4 piston will likely have caused the problem before you started hot-rodding, or if you’re attempting to fix it yourself. Luckily, the cracking could have been there for a while before the 6.4 diesel engine was ever in danger of starting.
Another sign of a leaking engine is the presence of oil dilution. If you’ve recently changed your oil, you may have noticed that you were leaking a bunch of oil. But the extra oil was not oil. It was diesel fuel that was injected late in the exhaust stroke, boosting the EGTs and burning off hydrocarbons from the diesel particulate filter.
Leaking fuel-water separator
My Ford 6.4 diesel is leaking fuel from the bottom of the fuel-water separator. The lower o ring is shot and the gasket is protruding from the drain manifold. Below are photos showing the problem. To fix the problem, simply replace the water separator and fuel filter. Do not try to fix the leaking fuel yourself, as a replacement may require more work.
The 6.4-liter Powerstroke engine is prone to a number of common problems, including a leaking fuel-water separator. While this diesel engine offers numerous improvements over its predecessor, it is still notoriously unreliable and notorious for failures big and small. Even though it is rare for a truck with this engine to reach the 200,000-mile mark without a catastrophic failure, owners who have not experienced the ugly side of this truck tend to swear by it anyway.
The leaking fuel-water separator is caused by a defect in the design of the engine. This component is meant to remove water from the engine’s fuel, but this process is not as simple as it sounds. Unlike the fuel filter, the fuel-water separator is not designed to drain on its own. Once the fuel-water separator is clogged, it will no longer drain and will allow water to enter the fuel system upstream. The water can cause expensive damage to the high-pressure fuel system. Hence, Ford has implemented a new design for this unit.
If you suspect the fuel-water separator is leaking, you must perform a relative compression test first. The relative compression test will tell you if the base engine is causing the problem. If the pistons are cracked, it can also mean a problem with the injectors. Occasionally, the popping sounds can indicate broken rocker arms. So, if you suspect a leaking fuel-water separator on Ford 6.4 diesel, be sure to check it first.