started removing stuff for the egr delete im a tad stummed on how to get the top fan shoud off cause i dont see any bolts to remove also i was talking to our local diesel shop an he told me to remove the flap out of the intake that the intake elbow bolts to is that correct? the illistration that came with the kit the picture didnt even have the flap in it

 

If you mean the little shroud, then it's just held in by tabs. Use a screwdriver to release the tabs.





If your talking about the stator (sits between the engine and fan shroud) then it's four 15mm bolts that hold the stator to the engine.





The EGR throttle plate was on the late '04's, that butterfly is only held in by two bolts.




It's also recommended to leave the EGR valve plugged in electrically, either leave the valve in its stock location or remove and tie up to the side. Depending in what your strategy is, disconnecting the EGR valve wires can cause issues with the fan clutch reaching full rpm and/or loss of VGT vane cycle relearn.

 

ya that butterfly valve i was told to take it out when i do my egr delete. a;so ive never herd about the egr valve causeing those issue i may have to do more reaserch everyoe says to yank the valve and since its an 04 i dont have to wory about the cel light im getting a sct anyway. thanks for the info on the fan shrounds

 

Not everybody knows about the issues with unplugging the EGR valve electrically.

 

You shouldn't have to remove the schroud to pull the intake, there are however 2 bolts from the schroud that bolt into the intake. They are sunk in and you need a deep 15mm? to get them from the top an from inside the fan area. If you look right in between the intake and schroud you should be able to see the 2 locations. Also make sure you put tie-wraps on the fuel lines when removing the oil filter housing, this keeps them from slipping down in between stuff and making it a PITA to get to them.
If you are removing the cooler completely then I would cut that cooler mount off the intake toward the back pass side, don't cut into the intake though, what this does is it allows you to remove the intake with the turbo still installed, it's a huge time saver if you ever have to get back in there.

 

X2 with Bob and Lilpooh. I unplugged my EGR valve after ditching the EGR cooler and the VGT was all messed up because of my ECU stategy. For now, I have an EGR valve laying on the intake. For looks, I plan to put it back into the hole.

 

ok i got it all pulled and i got another few things to do while im in there