Found some instructions incase anyone is wondering.

1. Drain the secondary cooling system (secondary feeds, trans and EGR)
2. Remove air cleaner assembly and outlet pipe.
3. Disconnect the EGR valve coolant vent hose from EGR valve
4. Detach the coolant hose retainer from the EGR valve
5. Disconnect the EGR valve electrical connector
6. remove the 2 bolts and the EGR valve inlet tube bracket
7. Remove the 4 bolts and the EGR valve inlet tube
8. Remove the 13 bolts and the EGR valve.

I really don't want to have to do all this just to pass emissions, but I guess the EGR valve is stuck due to soot over the years. Searching my code on this forum tells me the EGR valve is clogged.

 

This is the reason it is advised to run egr blocker plates ($70) when deleting. If you don't block off the egr, the next time you go to return to stock for whatever reason the EGR will be so coked up it won't work. Some report they are uncleanable and others report that cleaning gets them by. Do block off plates after you pass emissions and redelete

 

He said he did run block off plates

I'm curious though as to how long he was deleted before installing the block off plates??

I'm in the same boat as him and went about 2 weeks deleted before I installed the block off plates. Hoping my egr valve isn't clogged as well.

 

I would try cleaning it before buying a new one. I've had good luck with my harbor freight ultrasonic cleaner hot water, mean green, and dawn ultra. 2-3 heated 4 minute cycles and I've cleaned up some nasty stuff. Once clean blow it all out with compressed air. I've heard of other guys using pure pinesol on aluminum stuff with good luck.
I'm not sure what it would do to the electronics in it, but it's already not working, and my cpu tech buddy has been taking nasty computers to the car wash and cleaning keyboards in the dishwasher for over a decade.

 

I would try cleaning it before buying a new one. I've had good luck with my harbor freight ultrasonic cleaner, hot water, mean green, and dawn ultra. 2-3 heated 4 minute cycles and I've cleaned up some nasty stuff. Once clean blow it all out with compressed air. I've heard of other guys using pure pinesol on aluminum stuff with good luck.
I'm not sure what it would do to the electronics in it, but it's already not working, and my cpu tech buddy has been taking nasty computers to the car wash and cleaning keyboards in the dishwasher for over a decade.

 

I was deleted about 2 months before adding block off plates. I deleted when I got to 100K at 119K now. I'll give cleaning a try. Hopefully that does it.
Thanks for the help so far. I'll keep you posted.

 

Try brake keen and some new o rings/ gaskets. If that doesn't work get a new valve.

 

So update for everyone. For code P0403 EGR valve, when returning to stock.

1. I only had to drain about 3 gallons of coolant to remove the EGR valve. Since the EGR valve is high on the motor you can loosen all the screws for the EGR valve while draining the coolant and once the pressure equalizes stop draining the coolant.
2. I cleaned the EGR valve and the plate that goes behind it as best I could once off then reassembled everything, filled the coolant back up and gave it a try.
3. In the end cleaning did help but now I have a new code P043A which is ERG valve stuck open. I searched everywhere online and everyone says to just remove and clean, but if that doesn't work you need a new EGR valve. Thats me I guess, new EGR valve on order.

Here are some photos of the process of remove the EGR valve. Remember I deleted at 100K I now have 119K. I did use block off plates but installed them two months after I deleted.

Photo 1 Looking at the ERG valve with intake removed and a few other pieces
Photo 2 All bolts for the EGR are the same except one very long one
Photo 3 EGR removed
Photo 4 Dirty EGR
Photo 5 EGR after cleaning

 

Continuation

I also removed whatever the piece is between the EGR and the Cooler.

Photo 1 of the plate/spacer
Photo 2 how dirty this plate was
Photo 3 after cleaning
Photo 4 shot of the cooler with the plate off


Over all this job took me 4 hours as some screws were just so hard to put back in on the bottom side. There is a torque patter for all the screws that I got from my Ford dealership since there are 13 screws on the EGR and 8 more on the plate/ spacer.

So I'll wait till next week to try to pass emissions. Hope this helps others. In the end I'm kind of thinking the EGR valve went bad from not being in use, just my thought.
Code P0403 is gone but Code P043A is present.

 

If you're in that deep, might as well clean the cooler while you're at it. Flush some water and I think soapy solution through it and let it dry out before you reassemble. I'll see if I can find the thread on cleaning the EGR core.

May as well clean it that way its good as new if you ever had to return to stock permanatly

 

Installed a new EGR valve and the P043A code, EGR valve stuck open, is gone. I went ahead and cleaned the EGR cooler. One side of the cooler was almost completely clogged. After putting things all back together I have a new code for P0402 to much air going through the EGR. Since you can clear this code with the tuner and it takes 3 starts before it comes back I think I'll pass emission this time since I don't want replace more parts just to pass emission then put the delete back on.

 

I agree and glad you got it working enough

 

What was your egr valve cleaning process?

 

I passed emission today after clearing the P0402 code sitting in the parking lot of the diesel shop that performs emission testing. On the way home after passing I got a new code of P2073. Lucky for me a guy on this forum had this come up right after recharging this air filter which I also did to try to help pass emissions. All you have to do is pull the MAS (mass air sensor) and wipe of extra oil and code when away right away. Easiest one to clear.

To clean the EGR valve I shot it with an entire can of BerryMan B-12 carb/choke/throttle cleaner. I have done this on other cars in the past with great success. But in my case I think my EGR valve had mechanically failed or ceased up.

Returning to stock was not as easy as planned but now I'm a pro at removing and replacing everything, and learned a lot about the truck. Already re deleted over lunch today and back to the turbo whistle .. I'll be doing this again in another two years.

This forum was a great help seeing other has seen the same codes I had and could give me a starting point.

 

What difference does the EGR delete make to the engine? Better mileage?? Any other changes??
Thanks

 

Do you have any pictures of the EGR delete installed that you could post?
TIA

 

I didn't do a full EGR delete since I have to reverse everything every 2 years for emissions. Do you want a photo of the EGR block off plates installed? I can take one tonight for you.

 

Merlin,
That would be great. What turner did you use to delete?
Tia
Rick

 

Sorry @speedracer67 for the delay got distracted with home project. Here is your photo of the EGR block off plates installed, mine are from No Limit. If you do this remember to disconnect the ERG plugs there are two orange ones. You can only see one in the photo, there are threads on this so just search for it.

 

Do you know the locations of the emission sensors that need to calibrate before getting the emission check done? I am looking for the Exhaust Gas Sensor. It’s not a temperature sensor. This has been the only things keeping me from passing.