Home » 2007.5-2010 6.6L Duramax LMM EGR Delete Kit High Flow Intake Elbow Pipe Tube

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

Product: EGR Delete Kit & High-Flow Intake Elbow Performance System

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: DISASSEMBLY & FLUID MANAGEMENT

Step 1: Electrical & Coolant Prep

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

  2. Coolant Drain: Remove the passenger-side inner fender liner. Locate the lower radiator hose and remove the metal retaining clip to drain the engine coolant.

    • Note: Complete removal of the hose is not necessary; simply pull it back enough to allow a controlled flow into a catch bucket.

  3. Sensor Isolation: Loosen the intake hose clamps and disconnect the Mass Air Flow (MAF) sensor harness.

Step 2: Air Induction Removal

  1. Extract the primary intake pipe connecting the air filter housing to the turbo inlet horn.

  2. Carefully pry out the three rubber isolator washers and remove the air filter box and bellows assembly.

Step 3: Resonator Removal Loosen the hose clamp at the base of the top-mounted resonator box. Remove the long front mounting bolt and lift the resonator from the engine.

PHASE 2: INTAKE & INTERCOOLER DISASSEMBLY

Step 4: Grid Heater & Cable Tray

  1. Open the plastic protective casing on the intake heater grid and disconnect the primary power lead.

  2. Remove the two bolts and one nut securing the plastic cable tray to clear the workspace.

Step 5: Intercooler Plumbing

  1. Disconnect all electrical connectors at the front of the heater grid. Remove the wiring harness support bolts and plastic clips from the intake side.

  2. Release the metal retaining clip on the plastic intercooler pipe and separate it from the cast aluminum section.

  3. Remove the four bolts securing the mid-section of the cast intercooler pipe. Locate and remove the fifth mounting bolt at the bottom of the front section (securing it to the support frame).

Step 6: Component Extraction

  1. Remove the forward section of the cast intercooler piping, the throttle (butterfly) valve, and the associated hard plastic tubing.

    • Critical: Cover the open intercooler boot with a clean bag or rag to prevent coolant or debris from entering the system.

  2. Disconnect the small vacuum/pressure tube attached to the cast intake manifold near the heater grid.

PHASE 3: EGR SYSTEM EXTRACTION

Step 7: Intake & Turbo Inlet Horn

  1. Remove the four nuts and two bolts securing the cast air inlet section.

    • Tech Tip: Using a Reverse Torx (E-Socket) for the two rear bolts will significantly ease removal.

  2. Disconnect the PCV pipes from the driver and passenger-side valve covers and the turbo inlet horn.

  3. Loosen the V-band clamp and remove the plastic turbo inlet horn.

Step 8: EGR Cooler Removal

  1. If equipped, disconnect the two temperature sensors from the passenger-side EGR cooler.

  2. Remove the six bolts securing the EGR cooler. (Four are located at the rear—two facing forward, two facing downward—and two are located at the front).

  3. Lift the cooler assembly out and disconnect any remaining electrical sensor connectors.

Step 10: EGR Valve & Lines

  1. Remove the two bolts securing the EGR valve. Retain one bolt for the reinstallation phase.

  2. Remove the coolant return line that extends from the EGR cooler to the firewall (return wall).

PHASE 4: INSTALLATION & REROUTING

Step 10: Block-Off & Bypass

  1. Exhaust Block: Install the new exhaust block-off plate using the factory gasket. Secure the bracket using two M8x20mm hex bolts from the rear and two M10x20mm hex bolts.

  2. Coolant Bypass: Use the provided U-shaped coolant pipe and hose clamps to bridge the two ports on the heat exchanger. This creates a closed loop where the EGR cooler lines were previously connected.

Step 11: High-Flow Intake Elbow Installation

  1. Remove the plastic wiring harness cover and tuck the harness neatly beneath the path of the new intake elbow.

  2. Slide the High-Flow Intake Elbow into the rubber couplers and secure the bent end with the mounting bolts.

Step 12: Bracket Securement Use the provided M10 bolts to secure the two support brackets to the engine. Ensure the angled M8 hardware secures the intake elbow to the black bracket.

Step 13: Sensor Transfer Transfer the MAP (Manifold Absolute Pressure) sensor from the factory pipe to the new intake elbow. * Note: The mounting bracket must be rotated 180° on the sensor to align with the new mounting points.

PHASE 5: FINAL REASSEMBLY

Step 14: System Re-Initialization

  1. Reconnect the alternator (AC generator) charge wire.

  2. Reinstall the turbo inlet horn and PCV assembly. Secure the resonator box back onto the inlet horn using the factory hardware.

  3. Reinstall the air filter housing and intake piping. Reconnect the MAF sensor.

  4. Testing: Refill the cooling system. Start the engine and allow it to reach operating temperature. Inspect all fittings for leaks and top off coolant as the system bleeds.

POST-INSTALLATION ADVISORY

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

  • Thermal Check: Re-torque the exhaust block-off hardware after the first 100 miles of driving.