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2004.5 STC Upgrade

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Old May 4, 2019 | 07:19 PM
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2004.5 STC Upgrade

Hello people. Have a good question for y'all. I tore into my 6.0 today. i replaced the stand pipes and dummy plugs. I am at the point to where i am getting ready to do the STC upgrade {2004.5}. My question is should i take out intake and egr cooler to remove the top plate on the HPOP, or do it like Diesel tech Ron showed in his video. He says you can take the three passenger side bolts out of the cover with out taking out the intake. the thing i caught in the video, is he said they had already removed the the passenger side tab on back of cover witch made it easier. Mine is virgin in that area so i know all the tabs would be there. my question is, is it going to be enough of a pain and time killer where it mite be easier to go ahead and take out the intake. Will be on it in morning. Just want some advise from some one who has tried or done it that way. Thanks as always for your advise and expertise.

. I am right there now, Turbo is out and i am looking at it and not sure. I would just have to continue on one way or other.
 
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Old May 4, 2019 | 07:58 PM
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Just be aware that since you have a 2004.5, you have the old style HPOP. You can tell by the cast iron cover and the IPR valve screws into the cover instead of the HPOP itself. That means you don't have the troublesome/leak-prone STC fitting that is on the 05 and up engines.
 
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Old May 4, 2019 | 08:07 PM
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Have crank no start. 300 to 450 icp at cranking. Ficm 48. Icp volts .24. I replaced ipr, stand pipes and dummy plgs so far. Dont have preasure fitting so was gonna go ahead and do hpop. Was reading on not being the 2005 and up hpop when you answered any advise where to go from here. All tests with for scan , laptop version says all good with injectors and such.
 
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Old May 4, 2019 | 08:11 PM
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It could be a leak at an injector or two. Can't say for sure without an air test. Since your IPR is out I would get an IPR test fitting and pressure it up from there. Could also be a weak HPOP, the 04.5 is no better than the 03 HPOP IMO. I know the Adrenaline pump is expensive, but it has a very good success rate. Only you the owner can decide whether or not it is worth it. That said, I wouldn't button it up without the air test - even if you replace the pump.
 
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Old May 4, 2019 | 08:17 PM
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I am not a fan of the "square" EGR cooler either, unless it is one from BPD.

And be careful w/ the oil temperature sensor and oil pressure switch. It is easy to bump them a little hard and they can crack and leak.
 
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Old May 4, 2019 | 08:21 PM
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I'll be on the phone and the computer in the morning and get the fitting to go in the IPR slot I'll rig up an air fitting in a hose to that. I still have the driver side valve cover off so that would help I'm sure.
If it's injector leak will I be able to hear that with with the air test. Truck ran fine Thursday night ,like a champ. got home forgot something went back outside to start it up would not start. Went back out next morning it started up drove to the store. Came home hasn't started since.
 
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Old May 4, 2019 | 08:23 PM
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You should be able to hear it w/ the valve covers off.

Is that a little coolant under your blue hose?
 
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Old May 4, 2019 | 08:27 PM
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I don't know if you remember the post I had about my oil cooler being replaced a few months ago and they run the injector harness underneath the fuel and oil housing instead of on top between them.
I will take a look at those sensers. In morning.
 
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Old May 4, 2019 | 08:30 PM
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Yes it is. Thats another thing i saw and was wondering about. My egr cooler was deleted. Welded style years ago and i thought after they did the cooler it looked brand new. I guess the only way to see if they pulled something funny on me is to take it out and look.
 
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Old May 4, 2019 | 08:43 PM
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Inspect the IPR valve. Since you had an oil cooler job, you might have some lint/trash in it (the IPR).
 
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Old May 4, 2019 | 08:48 PM
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Replacd friday. Screen was clean on old one, but bought new one just in case. Same results 300 to 458 icp on crank. 58 or so koeo.
 
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Old May 4, 2019 | 08:52 PM
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Originally Posted by Visurveyor
Yes it is. Thats another thing i saw and was wondering about. My egr cooler was deleted. Welded style years ago and i thought after they did the cooler it looked brand new. I guess the only way to see if they pulled something funny on me is to take it out and look.
It may be unnecessary to pull the EGR cooler, but was it freeze plugs used or was a more solid plate steel used to block it off? Also, the coolant leak may just be the hose.
 
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Old May 4, 2019 | 08:55 PM
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Freeze plugs. If it is the EGR cooler leaking. Would that cause a no start.
 
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Old May 4, 2019 | 09:17 PM
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It certainly wouldn't cause low ICP numbers. Just something to consider when you are in that deep. I am not a freeze plug fan. Others may be ok w/ using them, but I would not be comfortable with them to plug the EGR cooler.
 
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Old May 4, 2019 | 09:24 PM
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Yeah that's what I thought. I'm racking my brain with things I've learned. and pressure test is the smart move first thing in the morning. get my line built put some pressure to it and listen to see what I hear.
Looked into the adrenaline pump. Wow. Will i hear a clear air noise coming from the pump if its bad?
 
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