I have a 2003 Excursion and am getting moisture on the EGR valve and coolant spewing out the small return hose. I filled the degress bottle to the high mark and drove about 200 miles and it was down to the low mark. The only thing i can think of is the cooler. I have posted other threads about delete kits and another motor being put in due to hydrolock in the last couple of years but am still having issues. i am looking at jumping in and pulling egr cooler today and testing it as best as i can. talking to a member last night we decided this is best then order full delete (thanks toreador).

so my questions are:
1. how can i remove the egr cooler without pulling intake manifold
2. where is the cheapest delete (no need to worry w/cel)
3. what gaskets, o-rings, seals do i need to order w/delete kit

i spent several hours last night looking here and there and got overloaded w/info so i am asking for help.

thanks,
Levi

 

Answers in red above.

I would also add that if you do have egr cooler problems, it is highly recomended that you change the oil cooler at the same time. I would flush the coolant system really good with VC9, install new Oil cooler (will require complete removal of intake), and install new Bullet proof diesel egr cooler (what I recomend) or egr delete

 

thank you texans. i'll let you know how it goes.

 

I would pick up the IPR Gen 2 delete.

 

Ok folks, I got the cooler out. Not a terrible chore but not a cake walk either. Ordered a delete and coolant filter setup, but I have another question. When I put all this stuff back together, do I need to replace o-rings on turbo as well as the seal for the oil line on top of the turbo? If so, what is the kit called and who has them. Thanks again for the help and if you could rep snuggyworm for his 45 min convo today over the phone helping me out.

 

Yes, you will need both of those parts. I believe they are included in the turbo installation kit. Tousley should have what you need.

 

Just call your local Ford dealer. You need a turbo install kit (see my first post). It's cheap like ~$20. Comes with new bolts to bolt down turbo. New O-rings for drain tube/feed tube, and new gasket for feed tube. They should have it in stock

 

Thanks guys. I'll give the dealer a call in the morning and should have everything else on its way ie. delete kit and coolant filter kit. We shall see how it goes. Thanks again and reps to y'all for the hand.

 

not a probelm. Let us know if we can help any more

 

Sorry for the late reply on the issue. I got the delete kit put in Thursday evening and in my rush to get it done I broke the coolant return nub off so pulled the radiator out and had it drilled/tapped and a metal barb put in. Put that back on and filled it up with ELC and some ATF for the tranny and so far so good. I also installed a coolant filter and the verdict is still out on that but for now, let the good times roll.

thanks again for all the help.