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need a cheaper hobbie
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46 Posts
Discussion Starter #1
not on this site much. anyway heres a write up i made a while ago. might help someone


Oil coolers not doing to good. this was at 50 degrees outside


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

grille off

a couple of buckets will be handy. one for oil and one for coolant

after 15 of rinsing soap out of the damn thing its good to go for coolant.

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

drained the oil

air filter goin away


get the shroud out of the way. kind of a pain

tubes coming off


radiator hose off

Get both battery's out before disconnecting the alternator

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.

pull the bots out

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

went and pulled all 3 fuel lines off. make sure you use line wrenches!!!

pulled the rest of the intake off. its bolted to the FICM

lots of CCV oil on my turbo. Turbo looks great for 50k miles of K&N

horrible picture but take the 4? bolts out around the base of the oil filter/fuel filter assessable

lift it on out of there

getting the first turbo bolt out. 1/4" ratchet, long extension and a wobble is your friend

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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need a cheaper hobbie
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46 Posts
Discussion Starter #2
lots of wiggling and tugging its out of there. remember to lift straight up first.

there's the good ol 03 turbo

pic of progress

take the turbo pedestal bolts out. looks like i got me a mouse nest

out

took the bolts out that hold the egr cooler to the intake. and all of the intake bolts

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

out

taking the egr cooler band clamp off the pass up pipe.

pull the little cover off the top of the oil cooler inlet

pull it up and it will come off

now you can pull the egr cooler out

pull all of the bolts around the oil cooler housing. once out i used a turkey baster to get the oil out.

cleaned up a little more

got all my new parts! thanks ups LOL

the oil cooler and cover

gotta pull this bolt out. then you can push the oil cooler out.

took the hotsy to the cover and installed the new gasket from the kit

put the new o rings on the new oil cooler

pushed it back in the cover

put the new HPOP screen in

took the hotsy to the intake. inside and out

put the oil cooler back in

heres the egr delete kit
 

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need a cheaper hobbie
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46 Posts
Discussion Starter #3
egr valve plate

took the valve out and installed plate

flipped over and put the coolant bypass on

all said and done

got the new up pipe in. i took out the pass side inner fender. made it a lot easier. major pain in the a$$

back on


all sorts of wiggling and the intake is back in. and egr delete is hooked up.

make sure you put the clamps on the other way. otherwise this happens

i always put anti seize on the pedestal bolts

in

new o rings on the turbo drain

new o ring on the turbo oil supply line

drain back in

all ready for the turbo to go back in


back in there.

hook up the feed line and put the bolts back in

after all that screwing around your fuel line bolts probably fell. a magnet will get them back

fuel and oil bowls back in. and bolts

fuel lines hooked back up

new filter goin in

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


more intake and alt
 

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need a cheaper hobbie
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46 Posts
Discussion Starter #4
rest of intake and drivers batt

get the belt back on and make sure its on all of the accessory pulleys

hot side pipe and battery (not shown)

got my insight

tapping for the probe.

ran the pyro

inside the old oil cooler

Now thats what im talkin about

first start after it was done:thumb:


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


dont know if i forgot anything
 

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Nice work man
 

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need a cheaper hobbie
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46 Posts
Discussion Starter #6
Thanks. Did I post it in the right section. I'm not real familiar with the nation


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need a cheaper hobbie
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46 Posts
Discussion Starter #8
lemme guss, the exhaust was hardest part to remove? nice thread by the way!
Yea it was a beast. I wish I woulda took some pics but I was to busy fighting it


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Gambled and Lost 6.oh
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927 Posts
It was horrible. I ended up using a 3' extension to go from underside and wrench wedged on top, would of been easier with 2 guys
 

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need a cheaper hobbie
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46 Posts
Discussion Starter #10
Yea it would have been 10x easier with 2 guys.


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Now I kick my seld in the @$$ for not doing it myself. If only I had the garage to get it in and not worry about people stealing my #### cause the door wont close
 

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2,081 Posts
This needs to be a sticky, or in the Library.

Thanks for posting all of this!
I'll be doing my first one next week. :doh:
 

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What are you using in the first pic to read the oil temp?
 

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Diesel Freak
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467 Posts
Nice man!!! let me get those mirror covers!
 

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need a cheaper hobbie
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46 Posts
Discussion Starter #15

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need a cheaper hobbie
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46 Posts
Discussion Starter #16

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Excellent write up! I will need to do this in the near future...my eot was 62 degrees higher then my ect on a recent trip. Thanks for the great post.
 

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need a cheaper hobbie
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46 Posts
Discussion Starter #18
Excellent write up! I will need to do this in the near future...my eot was 62 degrees higher then my ect on a recent trip. Thanks for the great post.
That's really scary man. Your egr cooler is not going to last long like that


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need a cheaper hobbie
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46 Posts
Discussion Starter #20
Yes I do. I'll post it up today


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