EGR delete
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From: East Helena MT
EGR delete
I decided to tackle the EGR delete on my 2008 F350 this weekend and it wasn't the most fun but it wasn't the worst thing ever either.
In all I had about 5 hours into it over two days, but thats because nothing was cut or hacked up, its all reuseable.
I tired to hook up my shop vacuum to the coolant system, to hold the coolant back while I disconnected the hoses for the EGR coolers. I have done this a lot in the past on changing out o-rings in hydraulic systems with out dumping the reservoir but I am sad to say it did not work on the Power Stroke so I had no choice but to drain the coolant from the radiator. In all it was just shy of 5 gallons. I pulled the upper radiator hose to gain more room for the project.
I removed the coolant hose to the vertical cooler and then went after the nuts for the flange between the vertical and horizontal cooler. One was easy, closest to pickup frame, the one closest to engine was a royal pain in the a__ but I did get it out. Then the cooler slide right out. Removing the top radiator shroud helps out a lot to get to bolts, the retaining bolt for the vertical cooler hose to the engine and also the vertical cooler mount once the cooler is out.
Next was the horizontal cooler which was a lot more of a challenge. The bolts that connect it to up-pipe were easy to get out along with clamps holding cooler. The problem was getting the cooler out. I was also not aware the coolant pipe to the cooler was bolted to the horizontal cooler mount, only bolt/part to be broken. It took a lot of wiggling and twisting to get the cooler to the front of the engine and up the front side but it did come out, barley and all while leaving the degas tank and y-pipe that always breaks.
Next was vertical cooler mount, with the radiator shroud out of the way I could easily see and get to the nut/stud holding the wire harness and power steering line that runs in front of engine. Then the rest of the bolts are easy and the bracket is out. I left the horizontal cooler bracket in place, did not feel like dealing with broken manifold bolts.
The install the intake manifold hook up air to air hoses and radiator hose.
Refilled with coolant and ran to make sure there were no problems.
I will say I had several error codes, one for throttle valve which I read on here I needed two resisters which I had and then today one popped up for egr temp sensor high voltage. Again, another resistor was needed. I measured the temp sensor and it was 268,000 ohms and I had a 68,000 ohm and it did the trick so far no error code. I am a little disipointed that my gearbox-z did not elemintate these codes.
Here are a few pictures of the project.
Jeff
Failed vacuum setup
Top half of fan shroud removed
Stud for harness and power steering hose that also holds on cooler bracket.
spacer in kit to fill space left by removed cooler for stud.
Pile of removed garbage from engine. Best photo of job!
In all I had about 5 hours into it over two days, but thats because nothing was cut or hacked up, its all reuseable.
I tired to hook up my shop vacuum to the coolant system, to hold the coolant back while I disconnected the hoses for the EGR coolers. I have done this a lot in the past on changing out o-rings in hydraulic systems with out dumping the reservoir but I am sad to say it did not work on the Power Stroke so I had no choice but to drain the coolant from the radiator. In all it was just shy of 5 gallons. I pulled the upper radiator hose to gain more room for the project.
I removed the coolant hose to the vertical cooler and then went after the nuts for the flange between the vertical and horizontal cooler. One was easy, closest to pickup frame, the one closest to engine was a royal pain in the a__ but I did get it out. Then the cooler slide right out. Removing the top radiator shroud helps out a lot to get to bolts, the retaining bolt for the vertical cooler hose to the engine and also the vertical cooler mount once the cooler is out.
Next was the horizontal cooler which was a lot more of a challenge. The bolts that connect it to up-pipe were easy to get out along with clamps holding cooler. The problem was getting the cooler out. I was also not aware the coolant pipe to the cooler was bolted to the horizontal cooler mount, only bolt/part to be broken. It took a lot of wiggling and twisting to get the cooler to the front of the engine and up the front side but it did come out, barley and all while leaving the degas tank and y-pipe that always breaks.
Next was vertical cooler mount, with the radiator shroud out of the way I could easily see and get to the nut/stud holding the wire harness and power steering line that runs in front of engine. Then the rest of the bolts are easy and the bracket is out. I left the horizontal cooler bracket in place, did not feel like dealing with broken manifold bolts.
The install the intake manifold hook up air to air hoses and radiator hose.
Refilled with coolant and ran to make sure there were no problems.
I will say I had several error codes, one for throttle valve which I read on here I needed two resisters which I had and then today one popped up for egr temp sensor high voltage. Again, another resistor was needed. I measured the temp sensor and it was 268,000 ohms and I had a 68,000 ohm and it did the trick so far no error code. I am a little disipointed that my gearbox-z did not elemintate these codes.
Here are a few pictures of the project.
Jeff
Failed vacuum setup
Top half of fan shroud removed
Stud for harness and power steering hose that also holds on cooler bracket.
spacer in kit to fill space left by removed cooler for stud.
Pile of removed garbage from engine. Best photo of job!
Thread Starter
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Elder User
Joined: Jul 2006
Posts: 930
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From: East Helena MT
It sure does clean up the engine compartment. I love my Ford pickup and the many others that I have owned over the years but I will say this is one area where Dodge and GM are way a head, engine packaging. You open the hoods of those competitive pickups weather it be gasoline or diesel they are well arranged, everything looks thought out and in place, verses later year Fords where stuff is just jammed packed where ever they can put it.
I should add that I had to pull the inner fender out to gain access to the horizontal cooler. Only 8 bolts/screws and a few minutes of time and it is out. I left the tire on, but I can see where I could get in easier to work. I have no problem taking parts off, but I like to take off just enough to get the job done.
The horizontal cooler is challenging because of the bracket, the steering column shaft, and the difference in positioning of the flanges on the cooler between front and back. The coolant line is also a pain in the rear.
I can see why people cut parts out to make this job easier. With a little more time this job can be done with out distroying parts.
Jeff
I should add that I had to pull the inner fender out to gain access to the horizontal cooler. Only 8 bolts/screws and a few minutes of time and it is out. I left the tire on, but I can see where I could get in easier to work. I have no problem taking parts off, but I like to take off just enough to get the job done.
The horizontal cooler is challenging because of the bracket, the steering column shaft, and the difference in positioning of the flanges on the cooler between front and back. The coolant line is also a pain in the rear.
I can see why people cut parts out to make this job easier. With a little more time this job can be done with out distroying parts.
Jeff
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Ron94150
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