STC-Pull the intake manifold or not?
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Cross-Country
Joined: Oct 2004
Posts: 80
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STC-Pull the intake manifold or not?
Getting parts lined up to update the STC fitting. Truck is an '05 with 92,000 miles.
Plan as of now is to flush the cooling system (Restore /RestorePlus/ ELC)
and drive it for a few hundred miles to make sure that the "delta" doesn't change. (Currently 4-7 degrees.) If the temp spread goes up after the chemical flush I'll do the EGR and Oil coolers when I do the STC.
Have the STC kit, a turbo mounting kit, updated oil feed and return lines.
Also have the standpipes and d-plugs.
Debating if I should pull the intake or not. I know that the STC can be changed with the intake on but is it worth pulling the intake to clean it(the intake manifold) and the added room while working on it?
Gaskets/parts needed if I do pull it?
Any downside to pulling it?
Plan as of now is to flush the cooling system (Restore /RestorePlus/ ELC)
and drive it for a few hundred miles to make sure that the "delta" doesn't change. (Currently 4-7 degrees.) If the temp spread goes up after the chemical flush I'll do the EGR and Oil coolers when I do the STC.
Have the STC kit, a turbo mounting kit, updated oil feed and return lines.
Also have the standpipes and d-plugs.
Debating if I should pull the intake or not. I know that the STC can be changed with the intake on but is it worth pulling the intake to clean it(the intake manifold) and the added room while working on it?
Gaskets/parts needed if I do pull it?
Any downside to pulling it?
Fleet Mechanic
Joined: Sep 2013
Posts: 1,303
Likes: 84
I just did this without pulling the intake. You either need to loosen at the least or take off the up pipe to the turbo if you leave the manifold. Otherwise is just puts up a fight. The down side to this is the bolts can be very crusty and break they aren't too bad to get to though. The down side to pulling the intake while not hard there is a lot more bolts that need to come out. You will be pulling the alternator, fuel lines to the banjo bolts from the fuel bowl. More than likely the radiator shroud and fan to get the rear should off to get to the Belt tensioner. None of this is hard just more to do. Now if you wanted to replace the serpentine belt an check the water pump this would be a good route. The up side once the Intake and egr cooler are out of the way it's a cake walk to get the hpop cover off and you don't have to mess with the exhaust bolts. I would pull the egr valve and look in on how dirty things are and then make the decision.
Lead Driver
Joined: Feb 2011
Posts: 8,241
Likes: 155
From: L.A. (Lower Alabama)
I would pull it. Only down side is a some extra time and maybe the gasket if you want to replace them. You may be surprised how filthy the EGR port in the intake is. If you need the truck back up and running quickly leaving it on is the ticket though. It's going to take a lot of degreaser and quarters at the car wash to get it as clean as you'll want it.
You may want a new intake gasket set, but they are reusable. Thick, plastic plates with the o-rings molded into them. I ordered new for my cooler swap but to be honest, I could have easily wiped the old ones down with wd40 and a clean rag and reused them. There is also a BIG o-ring between the front cover and the intake manifold and some metal gaskets at each end of the EGR cooler, all in reusable condition for me. A new EGR cooler hose is a good idea however, especially if your old one is orange instead of blue.
On a side note, if you STC is failing, you may not get a few hundred miles.
You may want a new intake gasket set, but they are reusable. Thick, plastic plates with the o-rings molded into them. I ordered new for my cooler swap but to be honest, I could have easily wiped the old ones down with wd40 and a clean rag and reused them. There is also a BIG o-ring between the front cover and the intake manifold and some metal gaskets at each end of the EGR cooler, all in reusable condition for me. A new EGR cooler hose is a good idea however, especially if your old one is orange instead of blue.
On a side note, if you STC is failing, you may not get a few hundred miles.
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Cross-Country
Joined: Oct 2004
Posts: 80
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I don't think the STC is failing....yet. From what I understand they can/will fail without warning so I would rather do it sooner than later.
Posting Guru
Joined: Jun 2012
Posts: 1,452
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From: Nor Cal
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Posting Guru
Joined: Jun 2012
Posts: 1,452
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From: Nor Cal
When I did mine, I didn't remove anymore than necessary. here's a picture of a tool I modified to get to the bolts under the EGR Cooler. It's a 5/16" box end wrench welded to the end of a flat screw driver and then bent to the proper angel
This made it a hundred time easies to get to the bolts. I'll post another picture of it
This made it a hundred time easies to get to the bolts. I'll post another picture of it
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Thread Starter
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Cross-Country
Joined: Oct 2004
Posts: 80
Likes: 3
Thanks for the replies.
The cooling system flush is done,it took ALL day yesterday.
Now it's just wait and see about the temps.
I'm going to pull and clean the EGR valve. Last time I cleaned it it was dirty but not terrible. I guess the condition of EGR/intake and the temp spread will determine whether or not I end up pulling the intake....
The cooling system flush is done,it took ALL day yesterday.
Now it's just wait and see about the temps.
I'm going to pull and clean the EGR valve. Last time I cleaned it it was dirty but not terrible. I guess the condition of EGR/intake and the temp spread will determine whether or not I end up pulling the intake....
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