Amongst the diesel community there’s a large number of 6.0L Ford Powerstoke engines with EGR problems. The exhaust gas recirculation (EGR) system routes exhaust gases back into the engine to lower nitrogen oxide (NOX) emissions produced by the engine. The EGR systems on the 6.0L’s unfortunately have a bad reputation of failing on both stock and modified trucks. By installing the XDP 6.0L Complete EGR delete your engine will run cleaner and cooler while increasing overall reliability. Below is a step by step installation guide to help you increase your 6.0L’s dependability and performance.
Install Tip: We suggest that a rust penetrant is applied liberally beforehand to all exhaust fasteners to ease the disassembly of exhaust components. (Step17)
Step 1: Disconnect Batteries
Step 2: Drain coolant
Step 3: Remove clips for plastic wire way located above turbo. Fold to windshield of truck and retain with plastic zip tie.
Step 4: Remove upper fan shroud by prying away from radiator through slots. (Note: The plastic can be very brittle)
Step 5: Loosen hose clamps and remove intake tube. Then unscrew bolts and remove turbo inlet tube and PCV Valve.
Step 6: Unbolt alternator and disconnect wires. Tilt alternator towards front of vehicle. Note: it is not necessary to loosen belt tensioner.
Step 7: Remove Turbo:
Intercooler charge pipe, Oil feed line from oil cooler to turbo (3 Bolts), VGT actuator harness plug, Up -pipe v band clamp, Turbo v-band clamp (downpipe), Turbo mounting bolts (3 Bolts)
Step 8: Once these parts are removed the turbo will rotate toward the passenger side of the truck and out of the pedestal.
Step 9: Remove the oil drain tube from the High Pressure Oil Pump Housing then Remove the turbo mounting pedestal (4 Bolts). *Early 03-04 (Pedestal will differ)
Step 10: Remove EGR cooler v-band clamp from up-pipe.
Step 11: Loosen the intake manifold bolts on the driver’s side. Completely remove the intake manifold bolts from the passenger side and note their location using a piece of cardboard. Remove the two bolts that go through the inner fan stator to the intake manifold (Located under the shroud).
Step 12: Remove the bolt that is used to stiffen the heater tube to the manifold (located below alternator). Bend this tab upward.
Step 13: Remove EGR cooler’s (3 mounting bolts)
Step 14: Lightly push down on the EGR cooler while pulling up on the intake manifold to disengage from the manifold.
Step 15: While holding the manifold up with a small pry bar move the cooler toward the back of the engine. Continuing to hold the manifold up, lift and remove the cooler through the front of the engine. Be sure that all gaskets and o-rings are removed with the cooler.
Step 16: Replace intake manifold bolts and torque to 120 (in-lbs.).
Step 17: Remove factory up-pipe: From underneath the passenger side of the truck remove the 2 bolts holding the up-pipe to the exhaust manifold. Once the bottom bolts have been removed, from the topside of the engine, loosen and remove bolts from factory up-pipe behind the heat shield.
Step 18: Install XDP EGR Delete Up-pipe with new gasket provided using the supplied hardware. (Gasket on top side)
Step 19: Install the 3/4” silicone hose on the ¾” 180 degree Stainless steel coolant tube provided. Loosely install hose clamps.
Step 20: Grease the EGR Cooler adapter o-ring. Place into intake manifold. Finger tighten the two longer factory cooler mounting bolts. The third smaller bolt can be discarded.
Step 21: Tighten billet adapter bolts to 120 (in-lbs.), while tightening make sure the o-ring stays in place and alignment is correct. Be sure not to over torque the bolts. Slide hose over the oil cooler nipple and tighten both hose clamps snugly.
Step 22: Remove factory EGR Valve from intake manifold and install XDP Aluminum block-off plate, use existing bolts and Torque to 120 (in-lbs.).
Step 23: Reinstall turbo, all intake and exhaust tubes including down pipe, alternator, shroud, wires etc. in reverse order from steps 3 to 17.
Step 24: Refill with new coolant, use manufacturer recommended and mix according to label.
Step 25: You are now ready to test your XDP EGR delete kit. Start engine and run till coolant circulates. Top off coolant system if needed. Make a close inspection for any coolant leaks or oil leaks.
Note: If vehicle throws a code or check engine light consider leaving factory EGR valve in place (05 models only). Alternatively, on 05-07 model years aftermarket tuning can be used to avoid any trouble codes. Contact XDP for details
Purchase the XDP 6.0L Complete EGR Delete Kit Here!