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Old 11-24-2012, 11:15 AM
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EGR Delete Questions?

So guys hopefully soon, I'd like to get the EGR delete on my truck, and I have a few questions. If I were to do the delete myself how long would it take me to do? I work at a firestation so we have a good heated bay that I can put my truck in. Also are there any cheap ways going about doing say an "homemade EGR delete? I was also wondering were those egr delete kits on ebay any good?
Any advice would be appreciated, Thanks
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Old 11-24-2012, 11:35 AM
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Spend the money on a good delete. Also, be aware that being an 06 truck there is a chance that your check engine light will come on if you don't have an SCT tuner with custom tune to shut EGR system off. First timer will take a good 6 hours to do delete.
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Old 11-24-2012, 11:57 AM
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Thanks 6 hrs isnt a bad time, so I should be able to knock this out in a day? depending if we dont have any calls. Anywho while looking on youtube I found this video of this guy using freezer plugs on the egr cooler,
and it seems like and cheap, and simple way to go, has anybody else used this method?
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Old 11-24-2012, 12:14 PM
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If your welding and fabrication skills are up for it you can make one yourself. You can keep it simple with freeze plugs welded into your cooler to block the exhaust and keep the stock look. You can go all out by removing cooler completely and making changes to the intake, weld it shut and fabricate a fitting to route your coolant to the oil cooler.

This is my version from 2008. Silicon tubing for the bend would have been an easier and faster job, but I was having a bit of fun with the design.

When I cut my EGR cooler in half to see what it looked like, it looked perfect inside. I guess it depends on what was in the system from the start or what got added over the years. For this truck, the EGR delete probably wasn't required.



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Old 11-24-2012, 12:20 PM
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Im liking that idea how hard was it to do?
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Old 11-24-2012, 01:02 PM
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The weld at the manifold was a PITA on the side due to cup/tip clearance. To do it again I would have welded in the first piece, then attached/welded the rest of the tubing. There were a lot if fitment adjustments to have it come to the right spot for the oil cooler. I was a little concerned about vibration on the long arm, but the tube is quite thick (1/8" I had laying around). If I would have had a piece of formed silicon tube available, I would have used that for the bend back and a good portion of the arm. I took a couple of hours to put it together, not counting getting to it.
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Old 11-24-2012, 01:20 PM
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Im hoping to take on all of this soon.
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Old 11-25-2012, 05:06 AM
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I decided imma go the way that guy did in the video with freezer plugs welded in. When I try an do this EGR delete will I have to do any gasket replacements, etc?
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Old 11-25-2012, 05:39 AM
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I'd do new intake gaskets if you completely remove the intake. Also, there is a big o-ring under the intake at the front that I would replace. When you remove the intake, that o-ring usually sticks to it so make sure you put one back or you'll have a huge coolant leak.
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Old 11-25-2012, 06:07 AM
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i followed Xtreme Diesel performance's instructions for the intake manifold. completely loosen passenger side intake manifold bolts(they say remove and mark locations, i just loosened them all the way and left them sitting in the holes), and then loosen the driver side bolts about half. this allows you to lift the passenger side of the manifold enough to get the EGR cooler out, plus you dont have to worry about lining gaskets and such up. if you really want to replace the gaskets, then remove it completely. just make sure you remember where all the bolts go in the manifold, because some are longer than others.

all in all the worst part is getting the turbo out, getting the old cooler out, and putting the turbo back. took me a total of 10hrs, but that included replacing the up pipe because i completely removed the EGR cooler. bolt it all back up, fill with coolant, let it run, cap off for a little while, top off as needed (with distilled water only!) and take it for a spin. i checked my coolant level every day for about a week just to make sure i didnt have any issues. i highly suggest having a friend help. they can help remove/replace turbo and hold the manifold up while you get the EGR cooler out.
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