So after much anxiety for the last 2 months (the total time I have owned my truck) my EGR cooler tanked. I will be doing the fix myself. I live in CA so I plan on removing the EGR cooler and cap welding it shut on both ends. Although now that I'm thinking about it, I probably don't want to weld a leaky cooler?... I will figure that out. Anyways, I will then mod and cap the up pipe as well. I will be replacing the oil cooler too. Since I will have her torn apart, should I do anything to the HPOP. My truck is a 2003 with 148000 miles. Its an auto and its all stock. thanks
Just had a thought. Since I'm living in crappy CA and I have to pass the visual inspection, I simply need to make it look like I have a well functioning egr cooler. I think I will pull my leaky one out, cut the underside out and rout a tube for the coolant. I will cap it where it mounts to the manifold and that should do it. Any thoughts? Anyone tried such a mod? I will be leaving my EGR valve in of course. Do I need a flash tuner to keep it all running smooth?
If your welds are good, you should be able to weld it up and if it leaks internally, it won't matter. The plugs at either end will prevent it from leaking into the intake.
If you are seriously THAT worried about it, chop the sucker open at the welds, rip everything out of it, block off the exhaust inlet and outlet flanges. The coolant will have nothing in there to slow it down.
WAIT, you have an 03... The Interior of your EGR cooler is the very same as the Bulletproof Diesel design. It has solid tubes that goes from one end to the other. Failure is NOT very common with that design at all..
Check the pic below. The egr pictured large is what you have STOCK. It has stainless steel tubes like that: Chances of that egr design getting anything in it that is large enough to slow coolant flow is one in a hundred million.
Weld the two exhaust ports and be done with it.
NOTE: The EGR that shows the "original design" is the later egr design, and NOT the 2003
Oh ok, I understand what your saying. I think that will work just fine. The egr cooler has definitely failed. Steam cleaned egr valve with a wet manifold and steam coming out the tail pipe. Thanks for you help
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