Replaced EGR Cooler with Bulletproof Cooler - Diesel Forum

Iron2 · 11-11-2009, 07:36 AM

I just wanted to post my experience with my EGR replacement from Neal Technologies Inc. (Bulletproof EGR). I called and got an answering machine stating to leave a message and they would return my call and they did, promptly.

I received the EGR cooler and was very impressed with the workmanship. One of the few good moments I had during the repair. While in there, I rebuilt the oil cooler and put the newest HPOP STC fitting kit (4C3Z-9B246-E) in. I did not have the 13/16 crowsfoot to properly torque the fitting. I spent a whole day finding that crowsfoot.

I boxed up the old cooler and sent it back with the provided shipping label. My core was credit immediately upon receipt.

I understand that a lot of people prefer a different solution to the factory EGR cooler, but if you choose to keep the EGR system intact, then IMO this is a serious improvement over the factory cooler.

Maui Stroker · 11-26-2009, 11:19 AM

Thanks for your feedback on the Bulletproof EGR cooler. I intend to do this upgrade myself. I've read here that some people think it's expensive but it seems like a full lifetime & legal solution to me - and kind of insurance against a potential engine catastrophe.

The smart approach would be for me to wait until the emission system warranty is up on my truck, right? It's a 2006 with 60k on. However, experience with the dealer out here is bad - I suspect there would be some excuse if the coolant/exhaust got mixed up and something broke as a result - I'd end up out of pocket big time anyway (somehow or the other).

I may just do this upgrade anyway in the next 6 months or so, so what is a reasonable time estimate for the work (competent DIY mechanic, fairly equipped, working solo)? You mentioned one specialist tool in particular, are there any other specialist items you'd recommend or other gotchas?

Iron2 · 11-27-2009, 01:12 PM

I rebuilt the oil cooler and replaced the HPOP STC fitting while I had the intake off for the EGR cooler. All together it took me about 8 to 10 hours, but could have done just the cooler in less than 8. The only tool I needed to find was a 15/16 (not 13/16) crow foot to set the torque on the HPOP fitting.

[FONT='Verdana','sans-serif']With plastic holding tool securely fastened, torque jam nut to 49 lb-ft (66 N-m) with a 15/16 crow foot open end wrench and torque wrench.
NOTE: TORQUE SPECIFICATION FOR STEP 8 IS CALCULATED FOR THE USE OF A CROW FOOT OPEN END WRENCH.[/FONT]