I just bought an EGR delete/bypass kit yesterday. I figured if I was going to take out the turbo I might as well do this at the same time. While I've got it torn apart I was planning on checking the y-pipe to make sure it didn't have any cracks. Let us know how yours turns out. I am waiting on parts right now so it will be a few days before I start tearing sh*t down. I'm am positive now that my engine temp is getting hot quick...are you having that issue too?

 

I would recommend an oil cooler swap while you're in there. I wish I would have done it when I did my EGR cooler delete.

 

My temps would get higher than they should if I was sitting in California traffic for to long but that problem is because my fan cut my fan clutch cables

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While you are in there I'd replace the oil cooler reconditioned turbo check icp pig tail for oil and if you can afford it replace the hpop I was just in the engine valley in Jan and I wish I would of replaced all the parts I have to replace now because I personally dread diving that deep into this engine

 

I would do all of that as well, minus the HPOP. Mostly because I'm cheap and I hate replacing parts that aren't broke. In the case of all the other stuff, it should just be replaced regardless.

Oil cooler rebuild kit is like $250.

 

Well...thought I should listen to everyone on hear and order an oil cooler while I'm at it. It will be here this weekend. Is there anything else I should get before I start this adventure? Do I need intake gaskets? I was going to open up the turbo and clean it all up as well. Anything I will need for that...gaskets, etc...? I want to be as prepared as possible before I get started. Any other suggestions or advice to make this go as smooth as possible? Any help would be appreciated! Thanks for all of the help and advice so far! You guys are awesome!

 

yes you will need intake gaskets, I know there is one kit that even comes with the turbo mounting and seal kit, if your dealer doesn't have that one go ahead and get the turbo mounting kit, like $11, if you tear the gasket on top of turbo you will need it anyway.
Just keep in mind if this is the 03 in you sig. tat the 3rd bolt holding the turbo on is hard to get to, alot harder then the late 04 and up ones so when you put it all back together you might want to consider leaving that back bolt out like I did, it makes removing the turbo in future alot quicker and it doesn't hurt a thing by it not being in there.
I always recommend for us 03-early 04 guys to try and find a later intake, makes life alot easier when it's time to change out the ICP sensor, and if you cut the tab off where the EGR cooler bolts to the back of the intake then you can pull the intake without even removing the turbo with the newer intakes. Just a note I have seen a couple on ebay selling for $85 and there is one on there now that even comes with the elbo so you can get rid of that butterfly housing under the old elbow.

 

When you cleaned the EBP and tube, did you also clean the fitting on the exhaust manifold? Mine was completly plugged up and ended up using a drill press and bit to get it all out.

 

Well SH*T!!! I finished putting in the new oil cooler and EGR delete kit this weekend and was feeling all proud of myself. I got her fired up and running and flushed the coolant before installing the new ELC coolant and all was going good. No leaks, no whistles...I was like a kid with a new toy. Then I went and drove it and she ran like a raped ape! I was having fun until I pulled back in my driveway and shut her down. When I got out oil was leaking everywhere! There was a trail of oil leading up to my driveway all the way down the street. It has to be a high pressure oil leak because when it was just sitting there warming up nothing was leaking...right? The oil sprayed from underneath all the way back to the rear driveline and all over the differential. I have no friggin' idea where it is coming from! Has anyone else experienced this or does anyone have any ideas of what the hell is causing this leak...and where I should start looking? I am at my wits end now!

 

Easiest way is to just clean it all up, and fire it back up and see if you can spot where it's coming from...

 

I found the leak. It is coming from where the oil filter housing mates to the oil cooler cover towards the front of the truck. Is there an o-ring that goes between those two parts? At least that is not a hard thing to remove (sigh of relief)!