Join Date: Jun 2008
Location: Brampton, Ontario, Canada
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Well, if you still intend on attempting this job yourself, you had better plan on at least two to three days of down time, if you are doing it with hand tools in your garage. For starters, you need to remove the air cleaner assembly (always remove as ONE-PIECE with all three pieces together), and both CAC hoses. You will then need to remove the turbo (three 10mm bolts including the aforementioned pain-in-the-a*s*s one), plus the two 10mm oil supply tube on the turbo itself). You will also need to remove the downpipe and y-pipe clamp (both 11mm or 7/16"). Spray LOTS of PB blaster or WD-40 into the clamps to break them free (especially the y-pipe one). If you are patient enough to have gotten this far, you will see why you were quoted the $2900. At this point you will need to remove the intake and EGR cooler. NOW, is the time to change the original EGR cooler hose (if it hasn't been already). The original one is orange coloured, the replacement one blue coloured (Ford part number RH-153). Don't forget to remove the oil/secondary fuel filter housing assembly. Zip-tie all your fuel line connections so they don't slide downward when disconnected. Don't forget the 10mm bolt that secures the passenger side fuel line to the intake, as well as the two 15mm bolts that secure the fan stator to the intake manifold. If you've gotten this far, now remove ALL the 10mm intake manifold bolts and studs (including the one under the downpipe), paying particular attention to its original locations. If you are replacing the high pressure oil pump, also replace the cover with the IPR valve assembly. Believe me, you don't want to have this apart twice! Order the part by "basic part number" 9G804 from Ford. This part is updated with an enlarged channel that prevents the outlet tube of the high pressure oil pump from rubbing through on the cover. This part is CHEAPER than the IPR valve by itself, go figure! Keep me posted on your progress, or the outcome.
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Ford Diesel/Senior/Master Tech who placed 2nd overall in Ontario on the Fix-It-Right-First-Visit score for 2010
....who works at a dealership that now employs SOME half decent looking female employees since they overhauled most of the administrative staff
....but STILL loves hot women with big boobies
....and STILL hates working on E-Series with 6.0L