Following the challenges with the 6.0L and 6.4L Powerstroke engines, Ford developed its own diesel engine, the 6.7L Powerstroke, internally nicknamed the “Scorpion.” This engine debuted in Ford’s Superduty lineup in 2011, marking a significant leap in performance and emissions control. Initially offering 390 horsepower and 735 lb-ft of torque, Ford later updated these figures to 400 horsepower and 800 lb-ft of torque, making it not only powerful but also the most emissions-efficient diesel engine in their lineup at that time.
Engine Design and Durability Features
The 6.7L Powerstroke, known for its durability, features a Compacted Graphite Iron (CGI) block, stronger than traditional cast iron, and well-suited for high horsepower and torque. The engine employs a deep-skirt block design and nodular iron main caps, each secured with six bolts, ensuring robust crankshaft mounting. The forged-steel connecting rods, akin to those in Cummins diesel trucks, and cast-aluminum pistons with offset pins and a single oil cooling galley, contribute to the engine’s capability to handle substantial power.
Innovative Cooling System
A notable aspect of the 6.7L Powerstroke is its dual cooling systems. The primary system cools the engine, while the secondary system manages the temperature of the air-to-water intercooler, transmission fluid, fuel cooler, and EGR system. This separation enhances the cooling efficiency and prevents issues seen in previous models, where coolant breakdown in the EGR system led to widespread system contamination.
Turbocharger Evolution: 2011-2016
Ford employed two different turbochargers in the 2011-2016 6.7L Powerstroke engines. The 2011–2014 models used a smaller, yet efficient, variable-geometry sequential turbocharger, while the 2015–2016 models were equipped with the Garrett GT37 turbocharger, known for its reliability and high-altitude performance.
Advanced Fuel Injection System
The common rail fuel injection system in the 6.7L Powerstroke features a Bosch CP4.2 injection pump and piezoelectric injectors, contributing to both performance and quiet operation. In 2015, Ford enhanced this system, increasing the pump’s stroke for more fuel flow and refining the injector nozzle tips for a finer fuel spray.
Emission Reduction and Reliability Enhancements
Ford significantly reduced emissions in the 6.7L Powerstroke by introducing Selective Catalytic Reduction and Diesel Exhaust Fluid injection, leading to fewer regeneration cycles and improved fuel economy. Additionally, the redesigned EGR system with an improved valve and dual coolers reduced the likelihood of clogs and malfunctions.
Detailed Engine Specifications
The 6.7L Powerstroke, produced from 2011 to 2016, features a V8 engine design with a 6.7-liter displacement. The engine block is made of CGI, with a firing order of 1-3-7-2-6-5-4-8 and a compression ratio of 16.2:1. It utilizes a high-pressure common rail fuel injection system and has varied horsepower and torque outputs depending on the model year.
Suspension and Steering Specifications
The 6.7L Powerstroke trucks come with different front suspension types based on the model, including Twin-I-Beam and solid twin-coil monobeam axles, with coil springs and gas-type shock absorbers. The rear suspension features a solid axle with leaf springs.
Cabin and Cargo Dimensions
The cabin and cargo dimensions of the 6.7L Powerstroke trucks vary based on the cab style, including Regular Cab, SuperCab, and Crew Cab. The specifications cover aspects such as height, width, ground clearance, load floor height, and cargo box dimensions, providing detailed insights into the spatial dynamics of these vehicles.
Towing Capabilities and Specifications
Towing capacity and specifications for the 6.7L Powerstroke trucks differ across model years. The guide includes comprehensive information on conventional and 5th-wheel towing capacities, helping owners understand the full potential of their trucks for hauling and towing purposes.
Key Features of the 6.7L Powerstroke Engine
- Robust Engine Block Design: Utilizes a Compacted Graphite Iron (CGI) block for enhanced strength and durability;
- Advanced Connecting Rods: Forged-steel connecting rods capable of withstanding high horsepower and torque levels;
- Innovative Cooling System: Dual cooling systems for efficient temperature management of the engine and auxiliary components;
- Turbocharger Evolution: Transition from a variable-geometry sequential turbocharger (2011-2014) to the reliable Garrett GT37 (2015-2016);
- Fuel Injection System Upgrades: Bosch CP4.2 injection pump and piezoelectric injectors for improved performance and quieter operation;
- Emissions Control: Introduction of Selective Catalytic Reduction and Diesel Exhaust Fluid injection, significantly reducing emissions;
- Redesigned EGR System: Enhanced design to decrease sludge build-up and clogging, leading to fewer malfunctions;
- Variable Horsepower and Torque: Different power outputs across model years, with significant improvements in later models;
- Diverse Suspension Options: Various front and rear suspension setups tailored to different models and applications;
- Versatile Towing Capacity: Comprehensive towing specifications, accommodating a range of hauling needs.
Comparative Table: 2011-2016 Ford 6.7L Powerstroke Engine Evolution
| Feature Category | 2011-2014 Models | 2015-2016 Models | Evolution Benefits |
|---|---|---|---|
| Engine Block Material | Compacted Graphite Iron (CGI) | Compacted Graphite Iron (CGI) | Consistent durability and strength |
| Turbocharger Design | Variable-geometry sequential turbocharger (SST) | Garrett GT37 variable geometry turbocharger | Improved reliability, performance at high altitudes |
| Fuel Injection System | Bosch CP4.2 injection pump, standard injectors | Enhanced Bosch CP4.2 pump, improved injectors | Increased fuel flow, finer fuel spray |
| Emissions Control | Basic emission reduction technologies | Advanced Selective Catalytic Reduction (SCR) | Dramatic reduction in emissions, better fuel economy |
| Cooling System | Dual cooling systems | Dual cooling systems with improvements | Enhanced cooling efficiency, reduced component exposure |
| Horsepower & Torque | Up to 400 horsepower and 800 lb-ft of torque | Up to 440 horsepower and 860 lb-ft of torque | Significant increase in power and performance |
| EGR System Design | Standard EGR valve and coolers | Improved EGR valve, dual cooler design | Reduced sludge build-up, decreased clogging risk |
| Towing Capabilities | Varied based on model and configuration | Enhanced towing capacity and options | Greater versatility and capability in towing |
| Suspension and Steering | Model-specific designs | Refined designs for improved handling | Better ride quality, handling, and stability |
Common Issues with the 6.4L Powerstroke Engine
In contrast to the advancements seen in the 6.7L Powerstroke engine, it’s important to acknowledge the challenges faced by its predecessor, the 6.4L Powerstroke. This engine, used in Ford Superduty trucks before 2011, encountered several notable issues that impacted its reliability and performance. Understanding these problems provides a comprehensive view of the evolution of Ford’s Powerstroke engines and the significant improvements made in the 6.7L model. Here are some common problems associated with the 6.4L Powerstroke:
- Radiator Leaks: The 6.4L Powerstroke often experienced radiator leaks due to design flaws, leading to coolant loss and potential overheating;
- Fuel Dilution in Oil: Oil dilution was a significant issue, where diesel fuel would mix with the engine oil, reducing its lubricating properties and increasing wear on engine components;
- DPF Clogging: The Diesel Particulate Filter (DPF) in the 6.4L Powerstroke was prone to clogging, affecting exhaust flow and engine performance;
- EGR System Failures: The Exhaust Gas Recirculation (EGR) system frequently encountered clogs and malfunctions, leading to expensive repairs;
- Turbocharger Problems: The turbochargers in the 6.4L Powerstroke were susceptible to failures, impacting the engine’s power output and efficiency.
Addressing these issues in the 6.4L Powerstroke was crucial for Ford in developing the more reliable and efficient 6.7L Powerstroke engine. The improvements and innovations introduced in the 6.7L model were, in part, a response to overcoming the shortcomings of the previous 6.4L engine.
Conclusion
The 2011-2016 Ford 6.7L Powerstroke engine represents a significant milestone in the evolution of Ford’s diesel engines, addressing the shortcomings of its predecessors and setting new standards in performance, reliability, and emissions control. From its robust CGI block design to the innovative cooling system and the evolution of turbocharger technology, the 6.7L Powerstroke has demonstrated Ford’s commitment to engineering excellence. The advancements in fuel injection and emissions systems have not only enhanced the engine’s performance but also contributed to a more environmentally friendly operation.
