Originally Posted by cheezit

first issue is blocking off the cooler. either delete it or run it.
second issue is exacly how do you dye test exhaust gas. if you refering to the blue liquid that stuff kinda sucks. best method is an IM240 machine.
follow tsb 09-08-03

Originally Posted by maniak88r

Hello, I am new here but not new to my 6.0. I have been chasing a problem for about a year and can't find it. If there is anyone that has ran into this problem before please let me know what you did to repair the problem. OK to start with my truck has had 6 EGR coolers and 7 oil coolers installed and that's just on this engine. The whole motor was warrantied at 38k. But back to the current problem. The cooling system is getting pressurized pushing water out of the cap. I have no oil/water, water/oil, water/diesel, diesel/water, etc. all the fluids are where they are supposed to be accept the water keeps getting pushed out. I pressurized the cooling system with a tester over night and it didn't even loose 1 pound. I checked the tank with the dye tester, no color change. I've changed 4 caps of all different brands, all the same. Upon cold start, I get no smoke at all and I've got 4" magnaflow with no-cat. If there was any coolant in the cylinders, I should see some white smoke or at least condensation. I just installed a new fan clutch, nothing changed. It is not getting hot, just pressure. I live in the foothills and the pressure seems to get drastically worse while I'm climbing a hill under boost, or towing a trailer. If this was a head gasket shouldn't it leak both ways? I am thinking a crack in the intake tract, either in the intake or the heads, but that too should leak both ways. Has anyone heard of the water pump slipping on the shaft? If that was the problem, shouldn't it be getting hot?

If anyone has any ideas, PLEASE HELP.

The truck has the following mods......
AIRAID intake
Magnaflow exhaust turbo back, no cat.
Banks charge air cooler system.
Edge Juice w/ attitude
RCD EGR Cooler delete kit