Home » 2007.5-2010 6.6L Chevy GMC LMM Duramax EGR Valve Cooler Delete Kit Fit

Compatibility: 2007.5–2010 Chevrolet / GMC Duramax 6.6L LMM

Product: EGR Valve & Cooler Delete Performance 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 & DISASSEMBLY

Step 1: Electrical & Fluid Service

  1. Battery Disconnect: Disconnect the negative cables from both batteries.

  2. Coolant Drainage: Remove the passenger-side inner fender liner. Release the metal clip on the lower radiator hose and pull back slightly to drain the engine coolant into a catch bucket.

  3. Sensor Isolation: Unplug the Mass Air Flow (MAF) sensor connector and loosen the intake hose clamps.

Step 2: Air Induction Removal

  1. Remove the primary intake tube from the engine bay.

  2. Carefully remove any securing zip-ties and unplug auxiliary wiring harnesses attached to the intake assembly.

Step 3: Intake Bridge & PCV System

  1. Remove the intake bridge/pipe secured by one (1) hose clamp and six (6) mounting bolts.

    • Critical: Cover the open intake ports with clean rags to prevent debris from entering the engine.

  2. Disconnect the PCV (Positive Crankcase Ventilation) hose located on the passenger side.

PHASE 2: EGR SYSTEM EXTRACTION

Step 4: Full EGR Assembly Removal

  1. Remove the four (4) bolts and nuts securing the EGR valve to the engine.

  2. Disconnect all coolant lines leading to the EGR cooler assembly.

  3. Extract the entire EGR valve and cooler unit from the vehicle.

    • Note: Retain the factory exhaust gasket for the installation of the block-off plate.

PHASE 3: INSTALLATION & COOLANT BYPASS

Step 5: High-Flow Charging Pipe Prep Pre-assemble the new charging pipe using the provided O-ring sealed baffle.

  • Tech Tip: Ensure the two (2) longer bolts are utilized on the front-facing side of the pipe for proper fitment.

Step 6: Bracket & Exhaust Block-Off

  1. Support Bracket: Install the new support bracket onto the engine using a factory bolt and the supplied M10 x 20mm hex head bolt.

  2. Exhaust Block-Off: Install the exhaust block-off plate using the provided 20mm and 30mm bolts. All hardware should be installed from the rear of the plate.

  3. Coolant Bypass: Replace the factory EGR coolant lines with the provided performance bypass hose. This creates a direct coolant circuit from the return pipe back to the thermostat housing.

PHASE 4: FINAL REASSEMBLY

Step 7: Intake Restoration

  1. Re-install the intake bridge. Ensure the front long bolts pass through the previously installed support bracket for maximum stability.

  2. Re-install the PCV hose, electrical wiring harnesses, and the intake resonator.

Step 8: System Re-Initialization

  1. Reconnect the alternator (AC generator) charge wire to the top terminal.

  2. Re-install the Turbo Inlet Horn (plastic interface) and the PCV pipe onto the turbocharger inlet.

  3. Secure the resonator box atop the inlet horn using the bottom hose clamp and the long front mounting bolt.

  4. Re-install the primary air intake and reconnect the MAF sensor.

PHASE 5: TESTING & QUALITY CONTROL

Step 9: Commissioning

  1. Refill the cooling system with a 50/50 mix of approved OAT coolant.

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

  3. Inspection: Check all block-off plates and coolant connections for leaks. Re-verify coolant levels after the first heat cycle or test drive.

POST-INSTALLATION ADVISORY

  • ECM Tuning: This hardware modification requires a compatible Race Tune to disable EGR logic and prevent "Limp Mode."

  • Maintenance: Re-torque the exhaust block-off hardware after the first 100 miles to account for thermal expansion.