Help on EGR cooler on a 2003 6.0 - Ford Powerstroke Diesel Forum
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post #1 of 4 Old 01-08-2010, 03:46 AM Thread Starter
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Question Help on EGR cooler on a 2003 6.0

Hi can anyone help me? I want to put in a EGR delete kit in my 2003 6.0. I dont want to give Ford $2600 to put in a new cooler only in a few years to go through this problem again. I purchased a good delete kit with all new gaskets for intake and the turbo. But I need to know if there is a service book out there that will give me a step by step on how to do the job? Also Is there a torque setting for the bolts on the intake? Does anyone have a ball park figure on time to do the job? Or has anyone done the job before that might be able to give me some info? Thanks......Joe
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post #2 of 4 Old 01-08-2010, 04:20 AM
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Here is a detailed write-up of the job. Hope it helps!
Complete EGR removal write up

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post #3 of 4 Old 01-09-2010, 01:16 PM Thread Starter
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tennstroke, Thank you for taking the time to show me this info!!! It will be a big help to me! You are a true gentleman! Thanks Again.....Joe
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post #4 of 4 Old 01-13-2010, 07:05 AM
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Just did oil cooler & egr delete on my '03. Fair mechanic. Book time 7 hrs., took me 15. Could probably do it in 8-10 second time through.Rear turbo bolt can be tricky on '03. Had to use a "bolt out" tool, short rachet and pry bar for leverage to get it after rounding out head. Huge time saver: DON'T REMOVE EXHAUST UP PIPE! Cut rear flange fitting off of egr cooler and weld a plate to it with mig welder(does a very good job) then bolt back on. Much easier and effective method. Follw the rest of the normal procedures. Prepare to cuss when trying to remove turbo, patience will bring you through.
Would do this mod again. Runs better than it has since new. Gives turbo a distinctive, different sound once you hit 13+ psi boost.
2003 89,000 miles
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