new oil & egr cooler, new problems arise
 

Hi, I'm new to the forums & was hoping for some help. I have a 04 f250 with 120,000 miles. I had a clogged oil cooler & bad egr cooler. I replaced the oil cooler with another stock one & put the bulletproof egr cooler in. I also added isspro ev2 coolant temp, oil temp, & fuel pressure gauges. New updated blue fuel pressure spring, hard line turbo oil supply line & coolant filter system. I just got it all back together & the check engine light came on after driving it for awhile I forgot to write the # down but it was excessive exhaust gas recirculation. Do I have a bad egr valve? I cleaned it & it didn't look bad is there anyway to tell if its bad? Ive heard of them sticking open but it was closed when I pulled it out. Also I just replaced both fuel filters & now I have a water in fuel light on. I drained the separator 3 times & its still on any ideas? Thanks in advance for your help!!

If it were me, I would get an EGR delete kit for it and be done with it. Any Emssions testing were you live? :w2:

What fuel filters are you using?

If you can get the code numbers that would help...

I'd love to do an egr delete!!!! but for now Im stuck in the wonderful state of California smog checks everyother year :td: I'm using fuel filters from the ford dealership & Im pretty sure the code was p0402.

just unplug the egr valve for now, on the 04 it shouldn't give a check engine light, and before you plug it back in for the smog test pull it out and vacuum the area out then reinstall, this will help keep any clumps from entering intake

Just exactly how much crawling around your rig do the smog nazis do? My point is that the EGR cooler is mucho difficulto to see and I am having no issues with a cooler delete and EGR valve in place. Upon seeing an EGR valve in place they may be less likely to look for the missing cooler.
Delete the cooler, if they give you any static about the cooler, leave, reinstall it and head to a different smog station. They can't PROVE you took it off so play dumb, "Clem's Muffler and Smog Shop" doesn't know how long you have owned that truck. I use to play dumb when I was in the Navy and had to smog my 67 Mustang. Heck, send the wife, they won't even think she knows what an EGR cooler is! It's not like they are going to drag you out back and shoot you in the back of the head for it.
If you really want an EGR delete, man up and do an R&R every other year for the inspection, I would now that I have done it. Sure its a lot of work, but sometimes you gotta work to put one over on The Man.

a 35mm freeze plug works great in the exhaust side of the egr cooler:w2: just sayin

Ya you're right I should have just said screw it & did the egr delete, but I didn't :argh: So for now I'm going to see how the bulletproof cooler does. I don't feel like ripping it back apart & dumping more money into it. If I have anymore problems I'll be doing a delete. Just unplugging the valve seems like a good idea. Any downsides to that? Also anyone have any ideas on the fuel in water light? I've drained it 4 times now & there was never any water in there.

The EGR valve isn't the problem, it's that big ol honkin scoop scavenging the exhaust gases that should be going to the turbo and shoving them back through the intake. I wouldn't recommend unplugging it, the computer could see the open circuit as a bad EGR valve. Like I said, I'm running a cooler delete only and no codes have popped.

it will not show a engine light, my 04 has been unplugged for 200k with no issues, also all these exspensive delete kits are insane, a 35mm freeze plug and then make a solid gasket for the intake side and you fixed it for $5, also the scoop you are talking about is for the 05 and up, 03s and 04s don't have them, just a heads up