I just removed my EGR cooler last week.

The reason I did it was that 5 years ago I blocked off the EGR cooler and right after I started having pressure in my coolant. It was not bad but if I revved the engine past 2600 the cooling system would pressurize, It would then drop back to 10PSI at normal cruising.

But lately it got worst and I assumed the EGR had a leak from day one and my block plate (possibly Leaking) was allowing exhaust pressure in the blocked EGR and pressurizing my coolant system more and more. It all felt like it was the exhaust pressure causing this pressure.

I do have all the gages and can observe all the important data.

I dought a head gasket would have lasted 5 years and only creating small coolant pressure.

Now, the coolant pressure stays lower then before and operate at about 3/5 psi. and if I floor it it will climb slowly to 15 psi and if I do it again it will go past that again saw as high as 20PSI.
Now my problem is a wet EGR valve passage area and I am loosing coolant. Do not see white smoke yet.

My thought at the moment is that the Intake Manifold Gasket did not sit well when I did the delete and water is leaking to the intake and the intake boost pressure causes coolant pressure.

I just bought the Head Gasket ARP studs kit but would like to solve the water loss first before doing the big job.

The truck has been great for the past 8 years, no injectors, just stuck turbo twice since new. I have 150K miles on the 2005 truck.

 

Intake manifolds do not connect to the coolant system except for the EGR cooler. I can't see how the intake gaskets can cause coolant loss.