Removing the EGR Coolers and Intake Throttle Body - Ford Powerstroke Diesel Forum
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Old 05-28-2013, 05:40 PM
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Removing the EGR Coolers and Intake Throttle Body

I am removing the EGR system this weekend and installing the Sinister EGR Delete kit with Intake Tube. I was wondering if there is anything I should look out for that is not mentioned in the directions? Are there any special tools that help make the job easier (i.e. swivels)? Some of the items I'm a little confused about is what does the plastic Y-pipe coolant line install to; what is it feeding coolant to? I'm assuming we are to remove the Y-pipe in order to remove the horizontal cooler without breaking the plastic coolant line. Also when re-filling the coolant system, does anyone have the step by step procedure to remove all air from the coolant system? Thanks for any help.
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Old 05-29-2013, 02:47 AM
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There is a good write-up here somewhere for both EGR delete and coolant swap process. You should flush the system while you have coolant drained in my opinion too.
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Old 05-29-2013, 02:53 AM
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Nothing special but doesn't hurt to have a swivel and or a wobble extension. A good socket set will get you through an EGR delete. IIRC one of the outlets of the y-pipe goes to the degas. Not totally sure but you'll see where it goes once you get in there. Not a huge concern.
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Old 05-29-2013, 05:42 AM
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Quote:
Originally Posted by 2008SleeperStroker View Post
There is a good write-up here somewhere for both EGR delete and coolant swap process. You should flush the system while you have coolant drained in my opinion too.
I agree with you sleeper I should flush the coolant system. But I don't have enough time on my hands to do it this weekend but I am installing a coolant filter so I'm hoping that will get me by for a while. I hear it is a lot easier to do the coolant flush with the egr coolers removed. So I will get around to it.
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Old 05-29-2013, 06:20 AM
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I remember needing an 8mm 12pt or spline socket to get one bolt out of the valve. Not exactly a special tool, but it's a little unusual if you just have a basic socket set.

I also got a lot of use from my ratcheting combination wrenches. Again, not an unusual tool, but not everyone has them.

I agree with the others that you should flush your coolant while you're at it. You have to drain it to remove the EGR coolers anyway, right? Why not go a little extra and do it right. It does take a little time though, you're right.

The coolant filter will help get the solids out of your coolant, ie sand and stuff, but it won't help with nitrates or pH or anything. And if your coolant is real bad, or gelling, the filter won't help once it gets full or clogged. It would be a good idea to flush it as soon as possible.

For getting air out of the system, I use an Airlift. It creates a vacuum in the cooling system, which sucks all the air out while also checking the system for leaks, and then sucks the coolant from the bottle to fill the system. It's a pretty nice device. There are a few companies that make variations of it.

As for the plastic y-pipe, I don't remember putting anything like that on when I did mine. I took a bunch of stuff off though..
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Old 06-02-2013, 06:24 PM
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I can't believe how long it took me to get those coolers out. Oh well I'm glad its done now but 18-20 hours later I am exhausted. I used to think I was a decent mechanic but I'm rethinking that thought. Luckily I got everything removed and installed without breaking or losing any thing in the fan shroud.
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Old 06-02-2013, 06:37 PM
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Holy crap, 18-20 hours? No wonder you thought it took a long time, because it did. I think mine was 6 hours start to finish, including clean-up, and scratching my head for a while trying to figure out how to remove that f'n lower cooler.

Maybe I have better tools than you do, or maybe I was more motivated due to the temperature being in the 40's and a foggy mist keeping everything (including me) soaking wet while I worked outside under halogen lights.

At least you got it done, that's the important thing. I think the end justifies the means.
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Old 06-02-2013, 07:36 PM
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maybe I'm not give myself enough credit. I was working and took a lot of breaks because I was getting so frustrated. I'm also out of shape and dont move as good i used to. Time to get to the gym. I think that's why it took me so much time. I'm also happy that I did it cause it look like one of my EGR coolers was starting to leak fluid. I found a pool of fluid in the throttle body as the exhaust enters the intake at the EGR valve.
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Old 06-03-2013, 09:58 AM
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My throttle body looked the same when I did mine
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