F150 3.0L Powerstroke

EGR Performance Kit

EGR30 INSTRUCTIONS

****Important note****

Some anti-seize is recommended for any exhaust bolts.

See manufacturers recommended specs for 

proper torque specs on each bolt. DO NOT work on a hot vehicle. 

ALWAYS allow the vehicle to completely cool before starting any work.

Step 1:

Drain coolant from the system. You will find the coolant drain looking up from underneath the radiator. See FIG A.

Step 2: Remove the plastic air filter housing, intake piping and engine cover to expose the EGR crossover  tube.           

Step 3: With the plastics removed you can now remove the EGR crossover tube and install the first block plate onto the intake. 

Step 4:Remove the electric connectors from the EGR valve as well as vacuum line running from the EGR bypass valve. You can fold the vacuum line over on itself and use a ziptie to block the line. SEE BEFORE & AFTER IMAGE BELOW.

Step 5: Remove the bracket holding the lines to the side of the cooler.

Step 6: Remove the bracket holding the dipstick tube to the back of the EGR valve. Two Bolts shown in Figure below.

Step 7: Now that you have access, remove the two bolts for the EGR pipe from the back of the valve.

Step 8: Remove the lines off the EGR cooler. One on top and one on the side (10mm).

Step 9: Remove the 3 bolts holding the EGR cooler to the brackets and carefully pull the cooler and valve as one piece. Then you can remove the 2 brackets that held the cooler to the engine. Remove the EGR feed pipe from the manifold and install block-off plate.

Step 10: Remove the EGR feed Pipe from the manifold and install block-off plate.

Step 11: Remove the 10mm bolt holding the coolant drain for the EGR cooler. See Figure (Before/After) Remove the coolant pipe and install coolant plug

Step 12: Install coolant feed block off plug, this is the hose that used to run to the top off the cooler.

Step 13: Using the brackets that were removed from the back of the EGR valve, remount the dipstick tube and exhaust back pressure sensor/tube and reroute the EBP wire. Be aware of hot or moving parts when running the EBP wire.

Step 14: Using a Zip tie, clean up the old EGR plugs.

Step 15: Pressure test coolant system then refill coolant and reinstall air filter housing and intake piping. Reinstall the plastic engine cover. Run the engine and check for leaks. If no leaks are present then you are finished.