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I did mine, wow what a difference. No more EGR and restriction in the Turbo up-pipe. My EGT's dropped 100+ and my water Temp's stay in the normal range. Before it was getting a hot and the cooling fan came on often. I also have noticed an increase in MPG and faster Turbo spooling. I got the new up pipe from http://www.elitedieseleng.com/60.htm
I used brake clean on mine while working it back and forth. I used a small screwdriver to hold it open then gave it about 3 coats of graphite thread spray already lasted 3 times longer than when ford cleaned it and still going strong. that said when I get closer to end of warranty will prob weld her shut and have done with it
unplugging the egr still leaves the egr cooler and oil cooler hot, and can set codes for engine light, i figure either clean and lube or eliminate that sucker completely
What about the cooling function of the EGR on the intake? If you block the EGR, won't it overheat? Those of us that live in SMOG states would really get whacked if it was seen that our EGR's were blocked.
the egr won't overheat if you block the line where it comes off the exaust, before it goes into the egr cooler. yes your emmissions will change but i figure a malfunctioning egr makes far more pollution than running without, I don't know offhand whether an idle sniff test would spot it. the function of the egr is to add an inert gas to the cylinder to reduce the temperature of combustion. atmosphere is roughly 21% oxygen with egr you may only have 15% oxygen or whatever. can you see where that could affect mileage,at 15% most people will be passed out and in pretty serious trouble