The main purpose of deleting the EGR is to avoid any EGR cooler issues down the road and keep from coking up your intake with carbon deposits. Some people say that having an EGR cooler blow lets coolant dump into the exhaust, which then makes it way into the cylinders. When it gets into the cylinders and is compressed and fired it turns into steam, which helps to stretch the head bolts causing a head gasket issue. This seems like a probable issue to me.
Not trying to be an a-hole, but you are wrong. The EGR cooler failure would allow coolant to directly enter the air intake stream whenever the EGR valve opened. The coolant would be introduced in the very same manner as the "cooled" exhaust gases. The coolant would then enter the combustion chamber and since liquid can not be compressed to the same extent as air (or vapors), that is what lifts the heads off the block. Not the creation of steam. The creation of steam as a byproduct of the combustion process would actually add power.
You don't have to pull the entire intake manifold to do the job. You will need to remove the turbo and loosen up all the intake manifold bolts. I like to replace the intake manifold gaskets also when I do this.
What I want to know is how do you get those new intake gaskets on without removing the intake manifold bolts?
No, the intake manifold does not need to be completely removed from the truck, but if your going to put new intake gaskets in, you will have to completely remove the bolts to do it. At that point, there really isn't much holding the intake manifold in anyway, other than that EGR cooler you are removing.
If it's an 03-05 you can remove the EGR valve totally. Since the EGR system is not working at this point it doesn't really matter anyway. If you have an 06-07 truck it seems like they will throw a check engine light if you delete the EGR. I know you can delete this if you have most chips now days. For example it's an option to delete the EGR valve thru SCT programmers.
I would suggest leaving the EGR valve in place, no matter what year your truck is. Since the EGR cooler is deleted, what exactly is the point of removing it? It will still open/close, but to what end? It will accomplish nothing, and there is some evidence that if you do remove the EGR valve it may cause issues with the "fan on" command, even if the EGR commands are deleted using an SCT tuner. That might only be the case on the later years, I would have to go through my notes on the subject and just don't feel like doing that at the moment.
Overall deleting the EGR system is one of the best things to do on a 6.0. It's just a matter of time before the EGR cooler blows or you have an EGR valve issue so why not get rid of it? Hell, the delete kits are going for way less then it would be to replace a EGR cooler or EGR valve anyway!
I agree. Delete if you can. Take into account pending legislation in your state before doing so, or you may have to reinstall your EGR system.
I, and many other people on this forum, used the $150 kit from Dicad solutions on e-bay. I have not read about anyone having any issues using that kit.