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A lot of times a tool with a sharp edge is used to dig into (and push out) that tab, and this can "lift up" a piece of plastic (as the tool digs in) and that gets in the way of its future movement. I wonder if a thin metal strip (needs to be flexible) could be "slipped" into the space between the slide tab and its "cover". Not that I have tried it - just thinking out loud.
Well today didn't go to plan at all, but I have it all put back together now minus the coolant. There was no way I'd get it all done today and 15cm worth of snow tomorrow then back down to -20c temps so this is something that will have to wait till spring. I cleaned the area where the leak was coming out with brake klean and a rag then rubbed RTV into the gap as best I could for a few minutes and rubbed a thick layer on top to finish it off and I'll wait till tomorrow to refill the coolant and see if she still leaks. I put some RTV on the rigid black coolant pipe as well just for good measure and cleaned it really good as well, but it wasn't dirty really and came out easily so that was nice lol.
I also figured why not check the intake manifold bolts to see if any were loose and sure enough I had to snug a few up a 1/4 turn so maybe that and the RTV will stop the leaking when cold and if not so be it. Also noticed the bottom end of the egr valve is pretty darn coked with soot or whatever, but egr is just there for show so not sure if that matters or not? Either way come spring I'll redo it all and put in an updated O Dog (or whatever it's called) intake manifold and all new seals etc.
You think by now I'd be use to the truck winning the majority of the battles, but it still stings
Also noticed the bottom end of the egr valve is pretty darn coked with soot or whatever, but egr is just there for show so not sure if that matters or not?
If you are EGR deleted, wouldn't this soot only be what was deposited from before you were deleted? I would think you could just replace the EGR valve with a cap or plug now.
LOL - you should try removing the '03 intake manifold with the turbo in place.
Quote from a flatrate tech:
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First off I have been a Flat Rate Tech for 10yrs now...I am all about saving time and making more money. Usually that is related by not taking parts off you don't "need" to. In this instance I think this actually cost time and money. How long did you F-with breaking the tab off the mani (ie tab that the egr cooler was mounted to)? Also that is just a horrible shot in the dark at hoping that the manifold doesn't break. It takes a whopping 10 min to pull the turbo out normally. With the oil filter housing out of the way, its like a 5 min job.
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So yeah - just break/cut a tab off (if deleted). Not recommended!
Nobody is talking about removing the intake, so what is your point?
If you are EGR deleted, wouldn't this soot only be what was deposited from before you were deleted? I would think you could just replace the EGR valve with a cap or plug now.
The EGR valve is needed for proper fan function. Deleting it can also reduce boost.
There are now three references to "tab" in this thread:
1. Rigid heater pipe mounting tab
2. EGR cooler mounting tab as part of the intake manifold
3. Red tab in the glow plug harness plug
If it's door #2 you're wondering about, it's this:
Still don't know why this was thrown into the discussion since a) you don't have a 2003, b) you're deleted, and, c) you aren't removing the intake.
OMG the earlier intake manifolds wrapped around behind the turbos lol. That's some sadistic engineering right there! Also that red tab in the glow plug harness I was having trouble with, well it clicked back over easily with a pipe wrench plier.
Refilled the coolant earlier today and no leaking after 6 hours and just now got the EOT/ECT up to 180f on high idle and no leaks so will wait and see what's what come morning. Since that O ring only leaks when it gets cold and shrinks I'm curious if removing the degas bottle cap when not running would prevent the leak by relieving any pressure in the system that may occur from temperature fluctuations and push the coolant past the shrunken O ring?
OMG the earlier intake manifolds wrapped around behind the turbos lol. That's some sadistic engineering right there! Also that red tab in the glow plug harness I was having trouble with, well it clicked back over easily with a pipe wrench plier.
I upgraded to a newer model intake without the bridge. What a difference it makes for doing repairs. Don't have to pull the turbo to remove the intake. Don't have to pull the intake to get to the HPOP. Easier access to the IPR. No downsides whatsoever.
Refilled the coolant earlier today and no leaking after 6 hours and just now got the EOT/ECT up to 180f on high idle and no leaks so will wait and see what's what come morning. Since that O ring only leaks when it gets cold and shrinks I'm curious if removing the degas bottle cap when not running would prevent the leak by relieving any pressure in the system that may occur from temperature fluctuations and push the coolant past the shrunken O ring?
Just a thought is all.
I don't know how long it takes, but when I get in my truck first thing in the morning, the coolant system pressure is always at zero. I think the leaking has more to do with materials contracting at critical connections than pressure in the system, but it couldn't hurt to release the pressure if you even remember every time you shut it down for the night.
I upgraded to a newer model intake without the bridge. What a difference it makes for doing repairs. Don't have to pull the turbo to remove the intake. Don't have to pull the intake to get to the HPOP. Easier access to the IPR. No downsides whatsoever.
Glad something went easily for you.
There's coolant under the truck again this morning so my efforts were unsuccessful sadly. I'm either going to have to just wait till spring to fix it myself or find a shop that has a large enough bay to accommodate the camper, but I'd much rather do it myself and know 100% that no dirt or debris gets dropped down into the cylinders.
That sucks. Too bad you don't live closer. I'd help you out.
It wouldn't be a big deal in warmer weather, but in -15c with 8 inches of fresh snow it would be a nightmare of a job, at least for me lol. Very kind of you thought
