Home » 2003-2007 6.0L Ford F250 F350 Powerstroke Diesel EGR Basic Cooler Kit

Compatibility: 2003–2007 Ford Super Duty F-250 / F-350 (6.0L Powerstroke)

Product: EGR Cooler Delete Kit with High-Flow Performance Up-Pipe

LEGAL DISCLAIMER & COMPLIANCE

OFF-ROAD USE ONLY: This high-performance racing component is engineered exclusively for competition or sanctioned off-road use. It does not comply with federal or local emissions laws for highway operation. Installation on any vehicle registered for public roads is strictly prohibited. The end-user assumes all legal liability and risk associated with the installation and use of this product.

PHASE 1: PREPARATION & COMPONENT CLEARANCE

Step 1: Electrical & Fluid Management

  1. Safety: Disconnect both negative battery terminals.

  2. System Drain: Drain the engine coolant into a clean container.

  3. Wire Routing: Remove the clips for the plastic wiring loom located above the turbocharger. Gently fold the loom toward the windshield to clear the workspace.

Step 2: Fan Shroud & Induction Removal

  1. Fan Shroud: Pry the upper fan shroud away from the radiator through the designated slots and remove it.

  2. Intake System: Loosen the hose clamps and remove the primary intake tube. Unscrew the mounting bolts to remove the Turbo Inlet Horn and the PCV valve assembly.

Step 3: Accessory & Charge Pipe Removal

  1. Loosen the clamps and remove the hot-side charge pipe (intercooler pipe).

  2. Unbolt the alternator and disconnect the electrical leads. Tilt the unit toward the front of the vehicle.

    • Note: It is not necessary to fully loosen the belt tensioner for this step.

PHASE 2: TURBOCHARGER & EXHAUST DISASSEMBLY

Step 4: Turbocharger Extraction

  1. Preparation: Apply penetrating oil to all turbo mounting bolts, exhaust up-pipe bolts, and pedestal bolts.

  2. Disassembly: Remove the V-band clamp from the rear of the turbo and the catalytic converter mounting bolt.

  3. Remove the two (2) oil feed line bolts, VGT actuator wire, up-pipe V-band clamp, and the three (3) main turbo mounting bolts.

  4. Extraction: Roll the turbocharger toward the passenger side and lift it out of the pedestal.

  5. Pedestal: Remove the turbo mounting pedestal and the oil drain tube from the H.P.O.P. (High-Pressure Oil Pump) cover.

Step 5: Exhaust Up-Pipe Removal

  1. From underneath the vehicle, remove the exhaust manifold bolts on the passenger-side up-pipe.

  2. Loosen the driver-side up-pipe bolts. While full removal is not required, loosening them provides the necessary clearance to extract the passenger-side components.

  3. From the top side, remove the bolts attaching the factory up-pipe to the Y-pipe. Remove the Y-pipe and unbolt the up-pipe from the EGR cooler to fully extract the factory assembly.

PHASE 3: INTAKE MANIFOLD & EGR COOLER REMOVAL

Step 6: Manifold Preparation

  1. Driver Side: Loosen, but do not remove, the intake manifold bolts.

  2. Passenger Side: Completely remove the intake manifold bolts.

    • Pro Tip: Use a cardboard template to track bolt locations for accurate reinstallation.

  3. Remove the two (2) bolts passing through the inner fan stator under the shroud.

Step 7: Cooler Extraction

  1. Remove the heater tube stiffener bolt (below the alternator) and bend the tab upward.

  2. Remove the three (3) EGR cooler mounting bolts.

  3. Use a small pry bar to lift the manifold slightly while pushing down on the cooler to disengage it. Move the cooler toward the rear of the engine, then lift and remove it through the front. Ensure all old gaskets and O-rings are removed.

PHASE 4: INSTALLATION & BYPASS INTEGRATION

Step 8: Sealing & Manifold Torque

  1. Install the supplied Exhaust Block-Off Disk to the up-pipe using the factory V-clamp.

  2. Reinstall the intake manifold bolts and torque to 120 in-lbs.

Step 9: Billet Adapter & Coolant Bypass

  1. Prepare the 3/4” silicone hose and the 180-degree Stainless Steel coolant tube with the provided worm-gear clamps.

  2. Billet Adapter: Lubricate the O-ring with clean grease and seat it into the intake manifold bore. Secure it using the two longer factory cooler bolts (the third smaller bolt is discarded).

  3. Precision Torque: Tighten the adapter bolts to 120 in-lbs. Ensure the O-ring remains aligned. Slide the bypass hose over the oil cooler nipple and tighten both clamps.

Step 10: Performance Up-Pipe Installation Install the new 2” High-Flow Up-Pipe using the provided hardware and the included OEM-spec gasket.

PHASE 5: REASSEMBLY & FINAL TESTING

Step 11: System Restoration

  1. Reinstall the turbocharger, all intake/exhaust piping, downpipe, alternator, and fan shroud in the reverse order of disassembly.

  2. Refill the cooling system with manufacturer-recommended coolant mixed to factory specifications.

Step 12: Quality Control Audit

  1. Start the engine and allow it to reach operating temperature until the coolant circulates.

  2. Perform a rigorous inspection for any signs of coolant, oil, or exhaust leaks. Top off the coolant reservoir as needed once the system has purged all air.

POST-INSTALLATION ADVISORY

  • ECM Tuning: This hardware modification requires a compatible Race Tune to disable EGR logic and prevent Check Engine Lights (CEL).

  • Maintenance: Re-torque the exhaust hardware and check all hose clamps after the first 100 miles.