Hi Guys,

When I deleted the ERG cooler, I used the Sinister ERG delete kit. It went without any problem, but I just discovered that I have a coolant leak at the blue adaptor that goes into the hard pipe. When I installed it, I lubbed it and the o-ring completely and it went in ok.

Before I pull it apart to find out what is up, how did you press yours in and was there much resistance?

At this point, I'm not sure if its the o-ring or the adaptor, it could be either one.

Thanks,
Larry

 

I used the H&S kit and the plug seal was very tight on both trucks even though I lubed them up. I just used hand pressure to install.

 

We got things apart and back together with no leak this time. I checked the o-ring over very carfully with a strong light and a high power magnifying lens and could find no rip or break.

On the adapter, I found the smallest hole you ever saw. I don't know if it was the cause or not, but I wrapped the plug with some high temp tape I have left from a NASA job, replaced the o-ring, greased the inside of the tube, o-ring, and the adapter.

We allowed the truck to warmup for a half hour and with no leak seen, we drove it for 50 miles at highway speeds, checking things a couple times. No more leak.

I'n sure the hole was the cause, but the size was right for the amount of coolant I saw leaking.

There will be a email going to Sinister about it shortly.

All good for now.

 

Hey Larry, let me know if you need help from Sinister with that leak.

 

Thanks James. I hope my "patch" holds. But I did ask that they send me a replacement adapter.

If ANYBODY can have a problem it will be me, Bro.

 

Larry, hate to hear you are having yet another issue! Seems that EGR cooler wants to leak with or without it present. I got the same Sinister kit as you but have not installed it yet. Was the hole along a seam or close to an end? Just curious, I want to inspect mine before I put it on.
Thanks...........JB

 

There no seam close to it. The hole looked like a casting sand hole. I know these are not cast but at some point the metal is poured. The hole was the size of a straight pin point. A little ragged on the edge. Located near the o-ring groove. I don't have anything to be able to see if it has a matching hole on the inside, but a very intense light inside of the adapter did not show any light through the hole - that only means it makes a right turn or two inside.

This was nothing but a freak, one of a kind problem. I would not be concerned. You'er much more likly to have a torn O-ring. Be sure to grease it up good when inserting it.

I greased the inside of the tube, the o-ring and the adapter. They slid together very easy (both times ).

 

Thanks, I'll be sure to do that. Hope any other mods you do are trouble free, you've had enough surprises.