What Can Go Wrong with the 6.7 Powerstroke EGR System?

September 15, 2022

Having the 6.7 Powerstroke EGR system helps you manage emissions from your EGR valve. The 'Legendary 6.7' is one of the most significant diesel engines with the highest production. It is also the top three most reliable diesel consumer-grade truck ever. 

The Ford 6.7 Powerstroke takes second place to the 5.9L Cummins of 2003 to 2006.

As sterling as 6.7 Powerstroke is, there are some peculiar EGR problems to look out for. 

Thus, it would help if you had a professional Powerstroke service technician in Crown City, Ohio. So now, let's find out the Powerstroke EGR problems.

What is the 6.7 Powerstroke EGR System?

EGR refers to the Exhaust Gas Recirculation valve. It is a means for controlling carbon emissions. 

EGR helps to regulate the combustion chamber temperature to reduce nitrogen oxides (NOx). 

The valve uses a vacuuming system to clear the air or fuel mixture, serving as an EGR cooler. That way, it reduces the temperature in the chamber and eliminates the spark knock (detonation). 

4 Problems with the 6.7 Powerstroke EGR Ford System?

Clogged EGR Cooler

Is EGR bad for diesel? Gas emissions from diesel can mess with the EGR cooler valve. It's like having cholesterol or themits in the body. So, what does the EGR valve do on a Ford Truck? 

The emission sticks to the EGR cooler or valve and other sensors. So that's how it affects your 6.7 Powerstroke too.

EGR can be susceptible to clogging even in the Ford 6.7 Powerstroke. And that's because of the build-up of debris that causes the temperature to rise. You need to have the EGR cooler working; if not, the engine will overheat. That will cause reduced fuel economy and higher emissions.

Clogged EGR Valve

6.7 Powerstroke EGR valve can experience clogging due to fuel quality. Once debris builds up in the EGR valve, it tends to burn fuel faster.

Diesel produces more debris than gasoline when burning. The most common EGR problem with Ford affects the turbocharge. However, the best cetane level should be 45 and above for 6.7 Powerstroke. But it would be best if you cleaned the EGR valve regularly.

Leaking Fuel filter housing

A leaking fuel bowl will typically crack and start leaking. With a plastic cap and aluminum pump, it becomes more prone to cracks. The engine heat can cause the cap to wear out over time and start cracking. A high-quality filter cap will last longer.

Also, the o-rings can cause fuel filter leakages too.

Leaking filter will cause:

  • Slow-cranking
  • Engine stalls
  • Dripping fuel underneath the engine

Camshaft Position Sensor Failing

The CPS sensor resides at the bottom half of your engine block. That puts it slightly above the crankshaft damper. It controls the camshaft position, speed. That's what feeds the 6.7 Powerstroke computer (PCM) with information.

The PCM sensor helps adjust fuel delivery to monitor fuel levels and control engine timing. However, once there's a sensor failure, the PCM signal stops sending signals for fuel delivery. That means your 6.7 Powerstroke stops receiving fuel for running the engine. 


  • It would help if you cleared the EGR cooler regularly.
  • Replacing the 6.7 Powerstroke is a good maintenance strategy.
  • EGR cooler from the 2003 model has round surfaces.
  • EGR cooler from 2004 has square have and are longer.

Regular servicing and maintenance of the 6.7L Powerstroke will keep your engine in good shape.

When you need a professional service engineer for 6.7 Powerstroke in Crown City, Ohio, then it's got to be Riverbend Service Center. We run a reliable and trusted diesel truck repair center.

For inquiry and inspection, please speak with our technicians today!

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