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I have a 2003.

I bought an insight CTS and was getting the codes P0488 and P0407. Both EGR related, so I pulled the EGR cleaned it up and put it back in, I'm still getting the same codes. The truck drives fine except for:

When I pulled it it was slightly damp, not wet just sticky. I had attributed this to leaving it unbolted overnight during some rain and high humidity. I just pulled it again after a week and it was slightly wet.

At higher speeds (70-75) the biggest difference in EOT and ECT was 16 degrees. That was flooring it to pass people. Other wise it was steady around 10-12 degree difference. This was on a 70 mile trip and a 98 degree ambient temperature.

I've done that same trip 8 times since then and my difference has been between 10-15, depending on wind, slight hills etc. I'm driving through central Illinois so there isn't much variance.

The highest ECT I've seen was 196 and the highest EOT was 205. Normal driving in the 90 degree ambient over the last few days was 188-190 ECT and 202-205 EOT.

During the last two trips I ran diesel kleen because it was suggested that the wet EGR was unburnt fuel. I pulled the EGR valve and it was dry, I also jacked up the rear end of the truck over night. There was no pooling of coolant in the intake manifold, however it did have a slightly wet appearance.

I also have the orange EGR cooler hose which appears to have a slight leak on it.


I'm not getting any smoke and I haven't noticed any coolant loss. I'm thinking a good coolant flush will be my first step, any other opinions?

Here is a pic of when I first pulled it.
http://i.imgur.com/7pO2r.jpg
 

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I would do an EGR delete or a bulletproof EGR cooler, immediately.

If you flush it you might wanna get ready to replace that oil cooler. There are a lot of people who flush with good deltas then they have 20+ deltas. When you flush it, your oil cooler is going to catch everything that comes free.
 

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Whatever you do don't flush the system, unless you dont mind clogging the cooler more. Your egr cooler is most likely busted. With that color hose, it's been there a while. You can replace the egr cooler and maybe buy yourself some time. Install a coolant filter.

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I would do an EGR delete or a bulletproof EGR cooler, immediately.

If you flush it you might wanna get ready to replace that oil cooler. There are a lot of people who flush with good deltas then they have 20+ deltas. When you flush it, your oil cooler is going to catch everything that comes free.
Just to reiterate, it is a 2003, it already has the round style EGR cooler.

I don't think it has failed.
 

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Just to reiterate, it is a 2003, it already has the round style EGR cooler.

I don't think it has failed.
Ok.

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Just to reiterate, it is a 2003, it already has the round style EGR cooler.

I don't think it has failed.
Ok.

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I have a 2003 EGR cooler. I did the EGR delete and although my highway mileage has not changed - my in town mileage is AWESOME. I get about 20 MPG on the highway and my in town seems to have gone from 13-15 MPG to about 17-18 MPG. Is this supposed to have happened?
 

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I have a 2003 EGR cooler. I did the EGR delete and although my highway mileage has not changed - my in town mileage is AWESOME. I get about 20 MPG on the highway and my in town seems to have gone from 13-15 MPG to about 17-18 MPG. Is this supposed to have happened?
It will help a little with mileage. It doesn't matter what style cooler you have, it should be gone. If your valve is wet its either cracked or you HG's are already gone, period end of discussion.

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Just to reiterate, it is a 2003, it already has the round style EGR cooler.

I don't think it has failed.
FYI the 03 had a round cooler all right but it isn't the bulletproof cooler.
The round coolers failed just as much as the others. Their tubes were small and kinda flimsey. Bulletproof guts the cooler and puts their own heavyer duty tube bundle in the shell. It has bigger tubes that improve flow and aren't as easy to clog and are of stronger material.
 

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My opinion - Unless your truck is getting emissions checked - I highly recommend removing the EGR system with delete kit.

I was told to get an SCT Tuner to turn the EGR system from my truck, so it will not throw a CEL, but with 4 complete heat cycles and about 100 miles, my CEL hasn't even come on and my ECU hasn't thrown a code.
 
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