So while I was getting my fuel filter parts today I also grabbed the egr oring kit, 2 orings and gasket made of like thin aluminum, well I pulled my egr and cleaned it, it was caked horrificly, looked like previous owner didnt even know it was there but anyways cleaned the daylights out of it, nice and shiny replaced both orings and pulled old gasket and slid the new one on, well I go to put it back in and it didnt quite line up like it did not go down all the way, pushed and pushed so I just bolted it back up started the truck and it died, then started again was fine, now there is an extremely noticable whistle coming from the engine I'm gonna take a stab and say its the egr, now what could I have done wrong?

 

I think you answered your own question right there....the valve should be seated all the way before you bolt down.

 

And make sure you use lubrication on the o-rings...makes life easier.

 

so now my question is do you really have to put a ton of force on the egr to get it to sit flush I was afraid I was going to break it by pushing down so hard?

 

You shouldn't have to push down too hard. If the valve was really caked with carbon, the intake is as well. Did you clean the o-ring mating surfaces in the intake manifold and put a bit of oil on the o-rings?

 

ah that I did not do, how can I wipe it out without chunks falling into the intake

 

A real small vacuum attachment helps

 

so in conclusion you think it wont fit back in correctly cause theres probably so much gunk in intake and I need to clean the internal orings and lubricate them? also how bad is it to drive the truck for about 20 miles with the egr valve like this? should I wait until after work or wake up extra early and get my bum out there and redo the job?

 

That would be my guess.

As far as can you drive it 20 miles like that, you're on your own there. I wouldn't do it.

 

had my deisel tech tell me that if you break up what you can see in the manifold and then start the truck for a second that the manilfold will blow all the crap out and then put the egr back in and start the truck. It will be fine, it will not hurt any thing. Thats coming directly from a certified tech. Tricks of the trade...

 

ok update I redid the egr cleaning and oiled the O rings and did the inside of intake egr popped in with ease haha but the noise is still there sounds more of squeaking now could it be a pulley I hear a very loud whistling at around 40mph I'm guessing I have an exhaust leak aswell