Home » 2003-2007 6.0L FORD Powerstroke Diesel EGR Delete Kit Fits

Compatibility: 2003–2007 Ford Super Duty 6.0L Powerstroke Diesel

Product: Complete EGR Delete & High-Flow Bypass Kit

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 & Cable Management

  1. Safety: Disconnect both negative battery cables.

  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: Cooling & Intake Removal

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

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

Step 3: Alternator & Charge Pipe

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

  2. Unbolt the alternator and disconnect the electrical leads.

    • Tech Tip: You can tilt the alternator toward the front of the vehicle without fully removing the belt tensioner.

PHASE 2: TURBOCHARGER & PEDESTAL EXTRACTION

Step 4: Turbocharger Removal

  1. Penetrating Oil: It is strongly recommended to apply penetrating oil to all turbo mounting bolts, exhaust up-pipe bolts, and pedestal bolts before proceeding.

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

  3. Extraction: Roll the turbocharger toward the passenger side to disengage it from the pedestal, then lift it out of the engine bay.

  4. Pedestal: Remove the turbo mounting pedestal and extract the oil drain tube from the H.P.O.P. cover.

PHASE 3: INTAKE MANIFOLD & EGR COOLER REMOVAL

Step 5: Manifold Preparation

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

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

    • Pro Tip: Place the bolts in a cardboard template to ensure they are returned to their exact original locations.

  3. Stator Bolts: Remove the two bolts passing through the inner fan stator located beneath the shroud.

Step 6: EGR Cooler Extraction

  1. Heater Tube: Remove the bolt securing the heater tube to the manifold (located below the alternator). Bend the tab slightly upward for clearance.

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

  3. Removal: Use a small pry bar to slightly lift the manifold. Slide the cooler toward the rear of the engine, then lift it out through the front. Ensure all old gaskets and O-rings are removed from the engine valley.

PHASE 4: INSTALLATION & BYPASS INTEGRATION

Step 7: Exhaust & Manifold Sealing

  1. Up-Pipe Seal: Install the supplied Exhaust Block-Off Disk to the up-pipe using the factory V-band clamp.

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

  3. Coolant Bypass: Prepare the 3/4” silicone hose and the 180-degree Stainless Steel coolant tube. Position the worm-gear clamps loosely on the hose.

Step 8: Billet Adapter Installation

  1. Lubrication: Apply clean grease to the Billet Adapter O-ring. Seat it carefully into the intake manifold bore.

  2. Mounting: Secure the adapter using the two longer factory cooler bolts (the third smaller bolt is no longer required).

  3. Precision Torque: Tighten the adapter bolts to 120 in-lbs. Ensure the O-ring remains seated and the alignment is perfectly centered. Do not over-torque.

  4. Final Connection: Slide the bypass hose over the oil cooler nipple and tighten both clamps securely.

PHASE 5: REASSEMBLY & FINAL AUDIT

Step 9: System Restoration

  1. Reinstall the turbocharger, pedestal, oil lines, and VGT harness.

  2. Reinstall all intake/exhaust piping, the alternator, fan shroud, and wiring looms.

Step 10: Commissioning

  1. Refill the cooling system with approved Ford Gold (or equivalent) coolant.

  2. Start the engine and allow it to reach operating temperature until the thermostat opens.

  3. Quality Control: 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) or "Limp Mode."

  • Maintenance: Re-check all hose clamps and turbo mounting hardware after the first 100 miles of driving.