EGR delete kit installation Guide-Step by Step
I have installed a River City Diesel EGR delete kit a couple of days ago, in F350. It took about 6 hours to complete the entire task. Here is part 1 of EGR delete kit installing Guide. I shall post part two on Friday 26th April.
First you should download and get a printout of the directions from Sinister. And then Take a piece of cloth or foam and put it on the engine. We need also “V” band clamps. Don’t remove the oil filter assembly, intercooler elbow/ duct. Now complete the deep well Metric (3/8”) and (¼”) drive set. Mech’s mirror and Rachet wrenches assist on a lot of spots.
Now at this point, check to install a metal gasket at the new down-pipe. Follow the instructions from Sinister and use the following tips;
A. Remove air filter
B. Take out the intercooler pipe with the connecting hose.
C. Cut off alternator wires
D. Open three mounting bolts. Be careful, it can tilt forward.
E. Separate ‘V” band clamp (from rear turbo).
F. Open two nuts from the tailpipe (this is under the passenger seat)
G. Untie exhaust manifold bolts (on drivers side) with a 10mm wrench and short socket
H. Do the same process on the passenger side. Take these exhaust manifold bolts completely out from the passenger side with a swivel socket.
I. Now disconnect “V” band clamp (Right side of the turbo).
I. Open three bolts from turbo. You can see it under the turbo.
J. Reach under turbo and pop turbo up, out of cradle.
K. Lift the turbo towards the mount. Be careful, it’s heavy.
L. Take away the turbo cradle two bolts from RH side and two bolts from LH middle side.
M. No need to take out the “Y” pipe from RH of turbo.
N. Take out the “T” pipe.
Click this picture for more “T” pipe.
O. Loosen the intake manifold bolts from the drivers’ side. These two nuts are holding the heat shield. After removing these, lift the shield up and untie the other 2 nuts, which are under the heat shield. Just loosen all the bolts here.
P. From Left-Hand side, take out all bolts so we can put them back in the same holes.
Q. To the left of the EGR valve, there is a stud. And also you can also see a bolt head both Stud and Bolt hold the EGR cooler. They’re used to install your bypass kit. Eliminate and stow them.
Installing an EGR delete kit 6.0
You may have heard of installing an EGR delete kit 6.0 on Ford diesel engines, but now know why some choose to install them. In your Ford diesel engine, the EGR serves to recirculate exhaust gas back into the engine cylinders. The exhaust gas, since it has already been through the engine once, is not combustible.
This results in less combustible fuel in your engine at any given time, which reduces the amount of nitrogen oxide emissions your truck produces. To an extent, this is good for the environment, which is why the EGR is in your truck in the first place.
But there is no question that the EGR results in less power to your diesel engine, which means you’re getting less out of your Ford. The engine simply does not have as much fuel to work with at any given time as long as the EGR is in place, and any unburnt fuel or oil in the exhaust gas can wind up somewhere in the EGR circulation system and cause problems. It can even increase overall fuel consumption.
There are other issues, too: the exhaust gas is very hot, which means before it is recirculated back into the cylinders it needs to be cooled. The EGR cooler is a significant heating element for the engine coolant at all times. If your truck has been modified at all – or even if it hasn’t – the EGR cooler can potentially boil your engine coolant, superheating your engine.
Engines without an EGR delete kit 6.0 might experience problems with the EGR cooler. Overheating and clogging are some of the most common sources of blown head gaskets. Even if everything runs smoothly, the EGR and EGR cooler raise your overall engine temperature, stressing your engine and reducing how much you can get out of it.
So, there is plenty of reason to bypass the EGR altogether in your engine using a Ford Powerstroke EGR delete kit 6.0. Since engine coolant isn’t being run through the EGR cooler system, it can circulate through your engine faster and remain colder, reducing engine temperatures significantly and letting you open up your truck without worrying about boiling the coolant. Managing temperature will also reduce your chances of over-pressurizing the coolant system and blowing a head gasket.
Installing an EGR delete kit 6.0 will also stop soot and residue in recirculating the exhaust gas from building up in the intake, a side effect of the EGR which in time can result in a reduction in horsepower. That same soot will also stop finding its way into the engine oil, wearing down your engine bearings after ending up in the engine oil system.
The EGR might be good for reducing emissions on a standard truck, but it is a system that is prone to failure and even when working correctly hurts your overall engine power and efficiency. A Ford Powerstroke EGR delete kit 6.0 can bypass the entire system and let you run your truck the way it was meant to run.
Installing a new Ford EGR delete kit 6.0 takes about six hours done professionally, though the time can vary depending on the kit you’re working with. Some basic kits only replace the EGR cooler and block off the up-pipe leading to the turbo. The more popular standard kit bypasses the EGR cooler and includes a block-off plate for the EGR valve and a stainless steel up-pipe that lacks the vents used to filter exhaust into the EGR, resulting in superior performance.
The basic process of installing an EGR delete kit 6.0 involves first removing the air cleaner assembly, FICM module, and turbo intake tubes. From there, drain the coolant, and continue with removing the turbo, EGR valve, alternator, injector harness, and intake manifold.
Many of these parts, especially the intake manifold, are well-secured with multiple bolts and clips, so be sure you’re up to the task before attempting to remove so much of your engine. If you do decide to tackle this one on your own, be very sure to keep all parts, bolts, and tubes properly separated and labeled so you can put them back later after installing your EGR delete kit 6.0!
Once all other parts are out of the way to EGR delete kit installation, you can reach and remove the EGR cooler itself. Use the included plugs and gaskets to block flow to the turbo feel pipe. The new stainless steel up-pipe can then be installed, all parts reassembled. Installing an EGR delete kit 6.0 might be slightly complicated for a novice, but for experienced mechanics, the process is fairly straightforward, and many professional garages can install your EGR delete kit 6.0 with ease