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Discussion Starter #1
I'm just finishing up on the EGR delete, oil cooler replacement, fuel pressure spring rreplacement and replacing the SCT fitting on the HPOP. Are there any special precautions or steps I need to take prior to starting the engine such as building oil pressure and fuel pressure? Any advice would be appreciated.
 

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cycle the key a lot before cranking it over to get the air out of the fuel system and get the oil pressure up. that help me a lot last week when i did mine.
 

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cycle the key a lot before cranking it over to get the air out of the fuel system and get the oil pressure up. that help me a lot last week when i did mine.

Cycling the key will purge the air out of the fuel system, but will not build oil pressure. The engine must turn over to build oil pressure.
 

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i never crank for very long for fear of overheating the starter. it's not going to fire on the first crank unless you filled the hpop reservoir
 

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Right, I didn't mean it to say that you just crank it once for that extended period of time.... crank for 15 to 20 seconds max....let the starter cool and do it again. When I did my BPD oil cooler it took 2 or 3 attempts, and I filled everything I could.
 

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Discussion Starter #8
Thanks guys. It took 3 or 4 cranks to get it to start. Runs like a champ and no more white smoke when warm. Now I will do the same thing to the second truck this week to correct the 50 degree variation in the oil to coolant temperature.
 

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How hard of a job was it?
 

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Discussion Starter #10
Not that hard at all. I built a platform to straddle the front of the truck using a 4x8 sheet of plywood to lay on. That made it real easy as you did not have to stand on the bumper or other stand. The frame for the plywood was out of 2x4's. Had it all apart in one day and back together in 2 days. I think the hardest part was cleaning the inside of the intake. It was really gummed up with oil and soot/carbon. Reinstalled the EGR valve after the delete and no codes were thrown.
 

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Thanks for taking all the credit for work dad! I dont care if it is your birthday! but thanks for cleaning the intake for me haha.

side note to anyone doing a egr delete. we are using the IPR delete kit where the egr valve is still installed so it still looks sorta stock and I didnt throw any codes at all on my 06. Clean kit. Does the job well and the kit with oil cooler and gaskets were CHEAP!
 

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Not that hard at all. I built a platform to straddle the front of the truck using a 4x8 sheet of plywood to lay on. That made it real easy as you did not have to stand on the bumper or other stand. The frame for the plywood was out of 2x4's. Had it all apart in one day and back together in 2 days. I think the hardest part was cleaning the inside of the intake. It was really gummed up with oil and soot/carbon. Reinstalled the EGR valve after the delete and no codes were thrown.
Great idea about the platform. I sat on the radiator and had one foot on the battery support the other on the idler pulley. I had indentions from the radiator on my butt for 3 days after.

Also i pulled my IDM relay and cranked a few times to make sure my injectors had high pressure oil before firing. I also cycled the key a bunch took awhile but she fired off after about 4 cranks.
 

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Thanks guys. It took 3 or 4 cranks to get it to start. Runs like a champ and no more white smoke when warm. Now I will do the same thing to the second truck this week to correct the 50 degree variation in the oil to coolant temperature.
50*? :dunno: WHOA!!! Congrats on getting the first truck done. :thumb: Having something to lay on makes a WORLD of difference. Using a topside creeper or even some scaffolding really helps to keep your chest and stomach from getting ripped apart from the engine bay.

PS. Noticed that you are from Poulsbo. I spent a couple of years in Bremerton when I was stationed there. Glad to have you aboard! In case you haven't noticed, there is an active chapter in the Northwest called the Cascade Coal Rollers (CCR). You might want to check them out. :nod:
 

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Discussion Starter #14
Thanks for the information about the local club. I do want to make i t clear that my son (NadiS4) did the wrenching on his 06 while I was his tool boy, and specification looker upper. The next one with the hot oil is mine and it is an 04. We (hopefully him) will do the same thing to mine as we did to his.
 

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Discussion Starter #15
2004 STC fitting

Today I took the 2004 engine apart to perform the EGR delete, oil cooler replacement (50 degree variation between ECT and EOT) install the blue spring and the STC fitting. During disassembly I noted that the HPOP is a different style from the 2006 my son just worked on. The STC upgrade kit apparently will not work on the style that I have. Does anyone know if the 2004 engines have a problem like the later models? I hate to take it appart if there is no need. Any information would be appreciated .
 

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Don't bother, the troublesome years are 05 and 06
To clarify, the 2003 and 2004 engines have a different style HPOP and different branch tubes, so they don't have the STC fitting. All other high pressure oil system (HPOS) troubleshooting techniques are the same between years since they all are prone to issues with the HPOS.
 
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