Here is a little info I thought I would share about my EGR delete on the cheap. Total out of pocket cost was $68.17 Im not going to go into huge detail on dissassembly and assembly of the engine as there is plenty of that info already lurking around here aswell as plenty of good access to shop manuals. I will touch on the main components etc. Granted, this price of $68.17 was wholesale prices from ford on the few gaskets/seals I bought there, and I did the welding myself. However even paying retail prices and paying someone to do your welding, I dont see it being anymore then $120-$150. Anyhow, here goes my poor excuse of a how-to writeup.

Parts I aquired from ford:

3C3Z*6B898*AA (upper turbo oil feed line gasket) $4.39
W300012 (Two required, "O" rings for oil drain tube) $3.64 x 2
W301331 ("O" ring, for lower end of turbo oil feed tube)
F6TZ*9160*AA (Two required, Copper washers for fuel line at upper F/F housing) $3.29 x 2
3C3Z*9P455*AB (EGR valve gasket/ O ring kit) $5.41
VC*&*B (Gold coolant/anti freeze) $13.28

From a wholesale supplier of race parts (earls fittings, aeroquip fittings etc)

3/4" Male NPT--- 3/4'' Female NPT 90* aluminum elbow $14.83

Advance auto parts:

303618 (molded heater hose) $7.99

Lowes hardware:

3/4'' Male NPT --- 5/8'' barb fitting $4.40

Thats a list of all the parts I used, not including sales tax.

I started by removing the air filter/housing assembly and tube to turbo. I then removed the intake elbow and the CAC pipe from the charge side of the turbo. Removed the passenger side battery and removed tension from serpentine belt. Removed the alternator assembly. Removed turbocharger and pedistal mount. Removed intake manifold, then the pass side turbo up-pipe that has the EGR fitting on it. Thats pretty much it. Like I said above, I didnt get into detail on all of this as its pretty straight forward easy work. If anyone has any specific questions feel free to PM me. Also, there is plenty of workshop manuals on here that are availabe. Now for the pictures. Im in no way saying this is the best way to do it, its just the way I chose to do it and I think will work pretty well and is very inexpensive. Im not a professional welder so be nice about my craftsmanship LOL

 

 

Looks like a damn good DIY job to me..

Nice!!

 

Is that a bottle of fingernail polish in that last photo????
Seriously though, nice job.

 

Very nice work! I never thought of the -AN fittings,I had plenty of those around when I removed mine last year....darn

When I first saw the costs of the kits out there,I nearly fainted.

Thermal barrier coating ??

 

Why yes it is a bottle of fingernail polish LOL Its the only thing I had handy to mark my turbo when I dissassembled it. Wife looked at me kinda strange when I told her to give me some fingernail polish

 

Yeah the cost of the kits are absolutley rediculous. I mean $500-$630 for a little bit of LIGHT fab work and EASY welding, a few clamps and a piece of pipe. I can somewhat see the added cost for the FULL replacement up-pipe but still doesnt justify the huge bend over and let me brake one off in you price.

 

Glad to hear that is what you were using it for, I thought I was going to have to turn you in to the BFT police!

BFT: To Protect and Serve Tough

 

^^^^^That theres funny I dont care who you are^^^^^

 

OH MAN! I laughed so hard here at work people looked at me like I needed "special help". I need to see the other seven videos!

 

I was looking at your work bench. Did you build it just for this project? Looks clean.

Good DIY project.

 

No, It is brand new but I didnt build it just for this project. I just moved into my new house about two months ago and I built it about a month ago. My old house I didnt have a garage or basement so I needed a good heavy duty bench. I love having a garage, however I sure do wish my truck would fit in it LOL

 

You know, a way I thought about doing this, but decided against due to the cost, would be use an elbow like I used, but instead of having 3/4 female NPT got one with like a -12 male end. Then used some -12 braided line, a 180* -12 swivel fitting then just slid the other end over the nipple on the block and clamped it. If this ever gives me trouble thats what Ill do. Now that the cooler is out of there all I need to do is pop the turbo off to have full access to it all.

 

by deleting the EGR what performace or improved mileage will it give you

 

Suscribing