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Discussion Starter #1
All,

Still working to get my 2004 6.0 running. It turned out that only 7 cylinders were viable so I have a long block coming. It has the factory EGR cooler on it and I am looking to either delete it or put a better cooler on. As I have done hours and hours of research, I am still confused as the best way to go. I live in a state with no smog checks and if a cooler from bulletproof is the best option, then I am for that, but there is still a large debate I see in threads regarding if this is really better than a delete.

If I do go the delete option, it is my understanding that the best option is probably to get the cooler sealed so gases don't pss into it and leave everything else in place. Correct? There is a seller on eBay selling Manzo egr deletes which I don't think are made anymore and they appear to be the only ones selling them. These delete kits look like they come with a cooler that has been welded shut at one end.

Thoughts?
 

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I'd keep everything in place, including the Factory Blue Hose, TIG the cooler end up, be selective in what pipe config you get heading up to the Turbo and be advised you'll get a CEL on the delete. Some early 04s maybe not, but later and on, the CEL will show up on the delete.
 

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Thanks, I would keep the existing up pipe, and leave the sensors in place. I think my early 04 would not get the CEL light to come on due to this from what I have read.

The kit from Manzo looks to be a stockish cooler with the cooler ended closed off, and figured it was about the same price as paying a shop to close off mine, and comes with all the needed gaskets.
 

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Find frost plugs for both ends if you need it present for a visible inspection. Use green loctite or a comparable sleeve retainer with it. I've done a bunch this way with no issues. Personally I'd just delete it altogether. The early yrs 03/04 will throw a "soft code" but the newer trucks will throw a cel n need a tune to re map it.
I did my delete on my 03 back in 05 when the kits were 700 bucks cdn. Wish I knew the frost plug trick back then lol
 

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Discussion Starter #5
I have never heard of using frost plugs. There are no inspections where I am. So, the idea is you find plugs that are the right size to plug up the ports?
 
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