Home » 2011-2016 6.6L GMC Chevy Duramax Diesel LML EGR Valve Cooler Delete Kit

Compatibility: 2011–2016 Chevrolet / GMC Duramax 6.6L LML

Product: Complete 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: DISASSEMBLY & FLUID MANAGEMENT

Step 1: Electrical Safety Disconnect the negative cables from both batteries to prevent electrical shorts or ECM errors during the installation.

Step 2: Coolant Drainage & Resonator Removal

  1. System Drain: Locate the lower radiator hose. Remove the metal retaining clip and carefully pull the hose from the radiator to drain the engine coolant. Once the overflow reservoir is empty and the flow subsides, reconnect the hose and secure the clip.

  2. Resonator: Remove the two bolts securing the intake resonator and lift it out of the engine bay.

Step 3: Air Intake Extraction

  1. Disconnect the Mass Air Flow (MAF) sensor harness.

  2. Loosen the intake hose clamps and remove the air filter box, bellows, and primary intake piping from the vehicle.

PHASE 4: INTAKE & TURBO COMPONENT REMOVAL

Step 4: Intercooler & Throttle Body

  1. Disconnect the electrical connectors on the plastic cold-side intercooler pipe and the throttle valve assembly.

  2. Remove the intercooler pipe from the throttle valve using the integrated twist-lock connection.

Step 5: Grid Heater Preparation

  1. Disconnect the green electrical connector from the rear of the grid heater.

  2. Remove the protective plastic side cover and disconnect the red power lead.

Step 6: Harness & Bracket Isolation Remove the two intake pipe brackets and disconnect the electrical harness mounted to the top of the intake assembly to clear the workspace.

Step 7: Turbo Inlet Horn

  1. Remove the two bolts securing the PCV valve to the rear of the Turbo Inlet Horn. Carefully set the PCV valve and mounting bracket aside.

  2. Loosen the V-band clamp securing the plastic inlet horn to the turbocharger and remove the horn.

PHASE 3: EGR SYSTEM EXTRACTION

Step 8: Crossover Pipe removal Unscrew the five (5) bolts securing the EGR crossover pipe. This includes two bolts at each flange and one central support bolt. Remove the pipe.

Step 9: EGR Valve Removal Disconnect the electrical harness from the EGR valve. Remove the four (4) mounting bolts and extract the valve from the manifold.

Step 10: Cooler Disconnection

  1. Remove the four (4) bolts connecting the two EGR cooler stages together.

  2. Disconnect all five (5) coolant lines feeding the cooler assembly, including the internal transfer line between the two coolers.

Step 11: Cooler Extraction

  1. Remove the two vertical bolts on the front side to extract the primary EGR cooler.

  2. Remove the four (4) bolts securing the second EGR cooler to the exhaust bypass valve and lift the cooler from the engine bay.

Step 12: Bypass Valve & Block-Off

  1. Remove the exhaust bypass valve by extracting the two vertical mounting bolts.

  2. Block-Off Installation: Install the provided exhaust block-off plate using the new gasket and high-temp hardware included in the kit.

PHASE 4: COOLANT REROUTING & REASSEMBLY

Step 13: Main Coolant Bypass

  1. Return Line: Use the provided 5/8" coolant hose. Install the blue T-fitting directly into the existing return pipe located behind the turbocharger. Secure with the supplied large hose clamps.

  2. Thermostat Connection: Connect the 3/8" coolant line and brass barb to the front coolant port near the thermostat (formerly occupied by the front EGR cooler).

Step 14: Final Plumbing

  1. Connect the open end of the 3/8" coolant hose to the heater core return line at the firewall.

  2. Use the smaller hose clamps to integrate the remaining coolant lines (previously connected to the bypass valve) into the new bypass circuit.

Step 15: Turbo & Intake Restoration Reinstall the Turbo Inlet Horn using the factory V-band clamp.

Step 16: Billet Block-Off Installation

  1. Install the new Billet Aluminum Intake Block-Off Plate (with O-ring) where the EGR valve was originally mounted.

  2. Reinstall the two brackets, harness connectors, and the oil dipstick onto the intake assembly.

Step 17: Top-End Reassembly

  1. Reinstall the grid heater and throttle valve (secure with the 5 factory bolts).

  2. Reconnect the red power lead and the green electrical connector.

  3. Reinstall the plastic intercooler pipe into the throttle valve twist-lock.

Step 18: Final Connections

  1. Reconnect the throttle valve and intercooler pipe sensors.

  2. Secure the PCV valve back onto the Turbo Inlet Horn.

  3. Reinstall the air box and intake piping; reconnect the MAF sensor.

PHASE 5: SYSTEM TESTING

Step 19: Commissioning

  1. Refill the cooling system with the appropriate 50/50 OAT coolant.

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

  3. Audit: Inspect all block-off plates and coolant fittings for leaks. Re-check the coolant level after the first 24 hours of driving.

POST-INSTALLATION ADVISORY

  • ECM Tuning: This hardware modification requires a compatible Race Tune to disable EGR logic. Failure to tune will result in "Limp Mode."

  • Thermal Check: Re-torque the exhaust block-off plate after the first heat cycle.