The coolant port at the bottom of the intake manifold that normally feeds this "U" pipe is wide open. The small 1/4 vent line that goes to the coolant rez is un-hooked from the intake manifold and the hose is plugged with a bolt and a clamp. I have not removed the intake manifold at this time but there is no longer coolant flowing through it. Which brings me to my first question. If there is a outlet port to the EGR from the intake manifold there has to be a inlet to the intake manifold. What, and where, is feeding the intake manifold coolant?
The coolant exits the oil cooler, then is fed to the egr cooler (or the u-shaped pipe) and then goes to the intake manifold. It exits the intake a few inches forward of that, where the intake/waterpump meet. That junction is basically dead center/front. You have some of the flow in reverse in your question.
My guess would be that the previous owner has something installed at the junction of the intake and waterpump. There is a thick "donut" o-ring there, or at least there is supposed to be one there.
On to the next disaster. The small aluminum casting on the other end of "U" shape pipe (again I don't have this piece im just referencing to other known egr delete kits ) is missing. There appears to normally be two bolts holding it down to the oil cooler housing cover. This casting, and both bolts are gone and I am left with a hole sticking straight up at me (this is where it gets real messy) with some kind of brass bushing perhaps installed into this hole which is then tapped with NPT, a barb fitting installed , and 3/4 " heater hose coming out, looped over the engine, and back down on the drivers side into a fitting that is installed into the side of the thermostat housing where it outlets to the rad.
Ok, picture time. Here is a pic of the oil cooler cover. See where it says "coolant IN" and "coolant OUT"? The "coolant in" has a cover in place in the pic. This same cover is supposed to be on the "coolant out" port as well. On that piece your are apparently missing, there is a hose barb that a rubber hose slides on that feeds coolant to either the egr cooler or egr cooler delete.
Does this make any sense? Again if someone tells me how to post pics I will, or I can e-mail them to you. I am trying to return this to a proper EGR delete system without all this hack job so I have a few questions.
The descriptions worked for me.
I know how to post pics, but will let someone a little more "tech savvy" explain it all. I'll stick to stuff under your hood.
Is there normally a 1/2" NPT port on the side of the thermostat housing or is this something that has been modified?
Second, does anyone know which missing peices I need for the proper 'U' pipe to attach onto the top of the oil cooler housing?
First, nope. No such NPT port is supposed to be there.
Second, I would start by purchasing a proper EGR cooler delete kit and removing all of the modifications that were done to the cooling system.
By the sounds of it, you need that piece that goes on the oil cooler cover. The bad news is that I don't think that one part is sold separately, the good news is that there are a few members on here that have recently installed an oil cooling system that makes the oil cooler cover obsolete. If they haven't tossed it out, I'm sure you can pick it up fairly cheaply from one of them.
Next, you will have to go to Ford and buy a new "donut" gasket for the intake/waterpump junction.
The thermostat housing is a different matter altogether. Was the lower portion of the housing drilled and them had their creation installed low (which is part of the front cover casting) or is this part above that and could be easily removed by removing the thermostat and the housing in which it sits? It should be above the thermostat, if only for coolant flow when the engine is cold. If it is, that part is easily replaced by purchasing a new thermostat with the housing.
If you are going into the engine "this deep," I recommend replacing the oil cooler. You will literally be just a few bolts away from doing it.
Check out the step-by-step EGR/oil cooler link in my signature line for more information about all this.