6.0 Oil Cooler/EGR Delete Write up

2003KingRanch

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Heres a Writeup i made about a year ago. Thought it might help someone.

Started with the coolant flush...

-10 gal distilled water from hyvee ($0.88 gal) = $8.88
- 3 gal of zerex elc-1 concentrate (ordered from Napa @ 19.99 gal x 3) = $59.97
- bottle of vc-9 (got from ford $32.00) = $32.00


grand total = $108
plus $40 in diesel

note- run your heat on high during the whole process. to flush heater core

#1 i drove it for about 5 min to get the t-stat open. pulled the pet**** and drained it (only get 3 gal at a time)

#2 filled it up with hose water. drove it for another 5-10 min. drained it again.

#3 topped it off with 3 gal of distilled. drove it another 5-10. drained it. do it one more time so you have mostly distilled water in the system.

#4 drain it. put your bottle of vc-9 and top with 3 gal of distilled.

#5 drive it! i took the interstate. went half hour out then turned around. 1 hour of drive time.

#6 drain it. leave the pet**** out. put the hose in top of the degas and run the truck for 20 min with water flushing through it.
after that the water coming out should be clean.

#7 repeat #3 to get all distilled back in the system

#8 drain the 3 gal out. and fill with 3 gal of coolant.

done! drive it and top it off with the distilled as needed. NO MORE COOLANT!!


some of the nastiest coolant Ive ever seen came out of that thing. heres some pics.


f69add27.jpg

word of advice. get a buddy to pull the pet**** when the coolant is hot :hehe:

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first drain

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yummy

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another drain

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the coolant

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serious flush after the vc-9

My EOTvs.ECT temps dropped 5 degrees on the highway after it was all said and done.




Oil coolers not doing to good. this was at 50 degrees outside
photo-60.jpg


Ordered everything from mkm customs, oil cooler,gaskets,egr delete. - Basic Solution(TM) for Ford 6.0L Powerstroke With Sinister EGR Delete Kit, Oil Cooler and Intake Gaskets

Im going to post pictures the whole way.
:dunno: if we need another write up but oh well
Parts should be here tomorrow some time. starting the tear down in the morning.

See how it goes


Heres the cost so far....

Coolant flush-
-10 gal distilled water from hyvee ($0.88 gal) = $8.88
- 3 gal of zerex elc-1 concentrate (ordered from Napa @ 19.99 gal x 3) = $59.97
- bottle of vc-9 (got from ford $32.00) = $32.00


Grand total = $108
Plus $40 in diesel

Oil cooler, egr delete,and all gaskets. (from mkm)
$665.00

Edge cs,pyro,and dash pod
$404.57

Box of shop rags -$8
2 cans of carb cleaner - $10

4 gal of rotella t6 and motorcraft filter (from walmart :doh:)
$107

Total so far..... $1342.57

got her in the garage
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grille off
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a couple of buckets will be handy. one for oil and one for coolant
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after 15 of rinsing soap out of the damn thing its good to go for coolant.
photo-85.jpg

the pet**** is a 3/4" wrench. i put a small piece of hose on it to keep the mess down
photo-83.jpg

drained the oil
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air filter goin away
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get the shroud out of the way. kind of a pain
IMG_3740.jpg

tubes coming off
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radiator hose off
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Get both battery's out before disconnecting the alternator
IMG_3746.jpg

i decided to go heeman on the belt and just pull it off. also zip tie it off so it doesn't come off all of the pulleys.
IMG_3747.jpg

pull the bots out
IMG_3748.jpg

outta there! also took out the bolt out of the feed line for the heater core while i was there.
IMG_3750.jpg

went and pulled all 3 fuel lines off. make sure you use line wrenches!!!
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pulled the rest of the intake off. its bolted to the FICM
IMG_3754.jpg

lots of CCV oil on my turbo. Turbo looks great for 50k miles of K&N
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horrible picture but take the 4? bolts out around the base of the oil filter/fuel filter assessable
IMG_3756.jpg

lift it on out of there
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getting the first turbo bolt out. 1/4" ratchet, long extension and a wobble is your friend
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after i got all the bolts out i took off the v-band camp that holds the down-pipe on. a pry-bar might be helpful if its stuck on there.
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lots of wiggling and tugging its out of there. remember to lift straight up first.
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there's the good ol 03 turbo
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pic of progress
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take the turbo pedestal bolts out. looks like i got me a mouse nest
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out
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took the bolts out that hold the egr cooler to the intake. and all of the intake bolts
IMG_3769.jpg

now the fun part. working the intake out. take your time. make sure you dont rip off any connecters ect...
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2003KingRanch

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out
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taking the egr cooler band clamp off the pass up pipe.
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pull the little cover off the top of the oil cooler inlet
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pull it up and it will come off
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now you can pull the egr cooler out
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pull all of the bolts around the oil cooler housing. once out i used a turkey baster to get the oil out.
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cleaned up a little more
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got all my new parts! thanks ups LOL
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the oil cooler and cover
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gotta pull this bolt out. then you can push the oil cooler out.
IMG_3785.jpg

took the hotsy to the cover and installed the new gasket from the kit
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put the new o rings on the new oil cooler
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pushed it back in the cover
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put the new HPOP screen in
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took the hotsy to the intake. inside and out
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put the oil cooler back in
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heres the egr delete kit
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[/QUOTE]
egr valve plate
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took the valve out and installed plate
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flipped over and put the coolant bypass on
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all said and done
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got the new up pipe in. i took out the pass side inner fender. made it a lot easier. major pain in the a$$
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back on
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all sorts of wiggling and the intake is back in. and egr delete is hooked up.
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make sure you put the clamps on the other way. otherwise this happens
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i always put anti seize on the pedestal bolts
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in
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new o rings on the turbo drain
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new o ring on the turbo oil supply line
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drain back in
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all ready for the turbo to go back in
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back in there.
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hook up the feed line and put the bolts back in
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after all that screwing around your fuel line bolts probably fell. a magnet will get them back
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fuel and oil bowls back in. and bolts
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fuel lines hooked back up
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new filter goin in
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2003KingRanch

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first part of the intake back on and the cold side pipe and the upper rad hose on
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IMG_3835.jpg

more intake and alt
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[/QUOTE]
rest of intake and drivers batt
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get the belt back on and make sure its on all of the accessory pulleys
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hot side pipe and battery (not shown)
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got my insight
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tapping for the probe.
IMG_3855.jpg

ran the pyro
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inside the old oil cooler
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Now thats what im talkin about
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first start after it was done:thumb:

First start after EGR Delete/Oil cooler - YouTube

As for time it took me from 6 am 5/31/11 to 8 pm today. total of.... 25 hours. dont think thats too bad. considering i did it by myself .

Things to note.... use good sockets no Chinese bs. an 1/4" air ratchet is your friend. if you dont have one buy one or borrow one.

Also label anything you think you wont remember. sandwich bags and a sharpie
 

2003KingRanch

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thanks, yes its a sinster kit. super nice kit. much better then some of the cheap eBay kits Ive installed
 

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