To install EGT probe on my 2004 powerstroke, do I have to weld pipe nipple ahead of turbo?

 

If you are going for pre-egt's. I would install it pre as well, and all you do is drill a hole, you do NO welding, might grease the drill tip to keep as many shavings out of the turbo as possible.

 

Do I have to tap the hole?

 

Yes, you do. The truck has no stock fitting for it.

 

The pre-turbo is located in the driver side exhaust manifold. You drill and tap the manifold. If you would put a sensor in the up pipe you would have to weld a bung or use a strap to hold the probe .

 

If it is cold, after sitting over night, you can drill in about an 1/8 of an inch, then start the truck let it idle and drill the rest of the way through.....turn it off and finish the job.
Tapping can be done in quarter turn increments, then back out the tap and do the same again...this will keep the chips out of the exhaust manifold.

Did yo get your gauges from MotorHaven

 

Are you guys saying that you do not have to pull the exhaust manifold?

 

A lot of the guys do it without pulling the exhaust manifold. I did remove the manifold but I'm in the minority I think.

 

i put mine on the turbo down pipe right after the turbo

 

I hate to make this process harder than it needs to be but wouldn't it be a good idea to take the manifold off? I'm probably being paranoid but it really wouldn't take many shavings to ruin a turbine.

 

If you oil the area any bits of metal will clump together when drilling. Use a mechanics magnetic tipped pickup to get any bits, including those that might fall in.

 

Yes you are being paranoid, take your time and a good vacume sweeper or any of the ideas you see here are good. The manifold is cast steel not like forged.

 

So many folks have done install with the manifold still on the truck and not had any problems that I think you can do it just fine if you are careful.

If you are mechanically inclined and don't mind doing the extra work, and feel more comfortable with the added piece of mind you will have by removing the manifold and doing it off the truck, then go for it.

I removed mine and it wasn't that bad of a job, but now that I've held the manifold in my hand and know right where to drill and tap, if I were to do another one, I'd probably leave the manifold on the truck and do it that way.

 

It only took me 1 hour to R&R the exhaust manifold. I would just rather be safe than sorry. It would be my luck that I would be the 1 in 1 million to do it without removing it and killing a turbo. Also, I had two minor leaks that I was able to grind off the exhaust manifold and cure.