2011-2016 6.7 Powerstroke EGR Delete kit Installation Manual

Caution! 

Never work on a hot vehicle as serious injury in the form of burning can result if the vehicle has been in use. Allow the vehicle to cool prior to installation. Always Wear eye protection when working on or under any vehicle. 

Note: The use of penetrating spray can (and should) be applied liberally as soon as possible to all exhaust fasteners to aid in removal.

Kit Contents 

Step 1: Disconnect the negative terminal on both batteries. 

Step 2: Drain approximately 3 gallons of coolant from both the hot and cold sides of the radiator. Turn the drain 90 degrees counterclockwise, then pull outwards and turn an additional 90 degrees counter clockwise. 

Step 3: Unplug the MAF sensor that is located on the intake by releasing the red locking tab. 

Step 4: Remove the two bolts that hold the air intake resonator and air filter box using an 8mm socket. 

Step 5: Loosen the two clamps on the intake pipe and remove. Step 6: Remove the air filter box from the rubber mounts by pulling up.

Step 6: Remove the air filter box from the rubber mounts by pulling up.

Step 7: Disconnect the ¾” coolant hose clips on the two coolant hoses that route to the top of the EGR cooler and remove. Note that it may be easier to remove the grill and passenger side headlight to gain access to the lower egr cooler hose to radiator connection. 

Step 8: Remove the three hose clamps on the 5/16” coolant hose and remove the tee. Install the supplied 5/16” straight barbed fitting and two small stainless steel hose clamps. Note on 2015-2016 trucks, use the supplied 3/8” straight hose barb and two small stainless steel hose clamps to connect the two radiator overflow hoses.

Step 9: Install the supplied ¾” molded silicone hose from the degas tank to the disconnected port near the bottom of the radiator that was removed in Step 7 using the supplied hose clamps. 

 Step 10: Disconnect the quick connect coolant line from the metal standpipe that is between the egr cooler and the intake manifold.

Step 11: Disconnect the egr temperature sensor using a 14mm wrench and remove the short egr pipe using an 8mm socket. 

Step 12: Remove the longer egr pipe that is fastened with 5 6 mm bolts using an 8mm socket. 

Step 13: Unplug the harnesses on top of the egr cooler and vacuum hose by first removing the 90-degree fitting. Install the supplied vacuum hose cap and zip tie the harnesses to the PCM harness.

Step 14: Unplug the PCM harness from the PCM and secure out of the way.  

Step 15: Remove the two bolts that secures the wiring harness to the egr cooler using an 8mm socket. 

Step 16: Remove the two clips on the heat shield that are located on the passenger side under the egr cooler.

Step 17: Remove the seven bolts that hold the egr cooler in place using an 8mm socket. 

Step 18: Remove the 10mm nut that retains the EBP hard line to the back of the EGR cooler. Note that on 2015-2016 trucks, the nut is a 12mm. 

Step 19: Remove the egr cooler from the truck.

Step 20: On 2015 – 2016 trucks, it is optional to replace the heater core hose with the 2011-2014 version to maintain the coolant bleed line but is not required. 

Step 21: Install the supplied exhaust manifold block off plate and factory gasket using two of the supplied M6x20mm bolts with a 5mm Allen wrench. Install the supplied EGT Probe Adapter with a 5/8” socket and an aftermarket EGT probe, or one of the factories EGT sensors from the DPF system. 

Step 22: Install the supplied egr cooler pass-through plate using three of the M6x30mm bolts with a 5mm allen wrench.

Step 23: Install the supplied intake manifold block off plate using two of the supplied M6x20mm bolts with an Allen wrench. Ensure the O-ring is properly seated before installing. 

Step 24: Reconnect the quick connect coolant hose to the metal standpipe. Reconnect the top line to the brass barbed fitted from step 8. 

Step 25: Reconnect the pcm harness. Make sure the plugs are fully seated. 

Step 26: Reinstall all the intake components. 

Step 27: Refill coolant following factory specifications. Run the engine and check for leaks. After the vehicle has reached operating temperature, check coolant level and add as needed.

Complete