so I put a sinister full egr deleate changed the up pipe and everything well now I lost a little of the 03 turbo whistle
I also thought maybe I have an exhaust leak in my uppipe or something and I cant feel it and only does it under boost IDK
but I get good fuel milage or average at 14 mpg and up per tank

And I do like that it looks stock

so I am thinking about doing the same as you
so is the intake end just have a freeze plug to or is it welded plate

also FWIW my 03 throws no codes from the egr deleate I checked with SGII and Innova code reader the Innova picks up on the codes better and nothing egr relaited

Im currios what your 03 will do as far as codes hope its like mine

03s RULE

 

You might be getting a low EGR flow code, which won't set the CEL, but can restrict the turbo vane range of motion in some strategies, leading the less boost, whistle, and performance. You'll get the same if you unplug the EGR valve.

On the intake side of the cooler, I am going to cut a flat plate of thin stainless steel (like 24 gauge) and sandwich it in between the cooler and intake with one of the original gaskets on each side of it. Probably will reuse the original gasket on the EGR cooler side rather than buy two new ones.

 

only code I get is like a P1000 or something nothing egr

and Iv seen 22-24psi boost according to SGII so who knows

IDK thats the only thing thats got me is the whistle is down alittle bit

just curios how you were going about your egr deleate

 

You might not be getting the Ford-specific codes, not all OBD-II code readers will get them. WOT from a stop, you should be seeing upwards of 27-28 PSI, the correct Ford procedure for testing that is WOT from a stop with it locked in 3rd gear to load the engine more than in 1st.

 

thanks for the info

I will try that test and see what I come up with

I did just go check my up pipe to exhaust manafold connection for soot like in your pic and was none
that connection was alot better built stock than after market IMHO

 

Mine is stock, did you think otherwise? There really are only a few aftermarket up-pipes and most use a better flex joint. EDE is one that offers an upgraded piece.

 

mine was the sinister egr deleate with just the one peice up pipe to change that eliminated exhaust to the egr cooler

Im thinking of going the same route you are though
stock and welded egr cooler ends heck its how I should have done it from the beginning changing that up pipe sucked I guess it wasnt that bad it would have been faster just blocking the cooler

 

Benny i get the p0401 code all the time , scangauge and actron will not pick it up, but my hypertech does. and if you are going to do the EGR cooler weld in stainless plugs, at least 1/8" thick then no problems.

 

I should have listened to ya the first time LOL

But the egr cooler is out so I just need to find a good welder now

Im going to let the kit ride for a min untill I get it welded

 

Holy overkill Batman!

 

how tight were the freeze plugs to push in

I know welding a plate eACH end would be bullet proff

but wouldnt just a freeze plug each end hold it cant move once its bolted back together as long as its a tight fit

 

I used a press, but it had a good amount of resistance going in. If you think about it, seeing upwards of 50-60 PSI backpressure (max) on a 1 3/8" diameter soft plug (1.5 square inches area) means it would be seeing less than about 75 pounds of force. It took way more than that to push it into place.

 

Thats what I was thinking and It couldnt go far all bolted back together

If the friction fit is good enought to seal it why not both ends and no welding IDK

 

Soft plugs aren't stainless steel, and so they could corrode out over time and eventually leak. I'm not worried about that. The stainless plate I have on the other end won't leak, so worst case is the cooler lets go and further down the line the soft plug starts weeping and I see white exhaust and know to replace the soft plug. I'm more concerned about coolant definitely not making it into the intake, which is why the plate on that end will be stainless.

 

Im with ya keeping coolant out of the intake is the main goal

can the plugs be found in stainless