The Ford 6.0L PowerStroke’s relationship with its EGR system often doesn’t lead to a happy ending. Many owners would agree that the EGR system was one of, if not the first concerns they had after purchasing their 6.0L. Due to the failing reputation associated with the EGR systems, XDP offers multiple types of EGR Deletes for this application. Our newest addition is the XDP 6.0L Basic EGR Delete Kit with Coolant Block-Off Plate (Part Number: XD186).
Using the same proven design as our standard EGR Delete Kit, the Basic EGR Delete is built with ease of install and value in mind. The specially designed Up-Pipe Block-Off Plate simply clamps in place to block the cooler connection of your factory up-pipe. This saves time, money and the hassle of working between the firewall when removing/replacing the factory passenger side up-pipe.
**For off-road use only**
(CA Residents: Not legal for sale or use in California on pollution controlled motor vehicles.)
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: Install the Up-Pipe Block-Off Plate onto your uppipe using the factory v-band clamp.
Step 18: Install the 3/4” silicone hose on the ¾” 180 degree Stainless steel coolant tube provided. Loosely install hose clamps.
Step 19: 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 20: 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 21: Remove factory EGR Valve from intake manifold and install XDP Aluminum block-off plate, use existing bolts and Torque to 120 (in-lbs.).
Step 22: Reinstall turbo, all intake and exhaust tubes including down pipe, alternator, shroud, wires etc. in reverse order from steps 3 to 17.
Step 23: Refill with new coolant, use manufacturer recommended and mix according to label.
Step 24: 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.
The EGR delete system should not throw a check engine light on 03-04 trucks. On 2005 models it has been noted that if the EGR valve is left in place the truck shouldn’t throw any codes. 06-07 models require aftermarket tuning such as an SCT programmer to avoid any trouble codes.
Purchase the XDP 6.0L Basic EGR Delete Kit Here!