DIY- EGR Delete Install on 6.4 Ford Powerstroke Diesel

DIY- EGR Delete Install on 6.4Powerstroke

Here are some step by step instructions on how to install your 6.4 Powerstroke EGR delete.

1. Make sure the front wheels are straight.
2. Disconnect both batteries.
3. Drain the coolant using the coolant drain plug located on the bottom of the radiator on the driver side.
4. Remove the 3/8” hose that runs to the degas bottle. *Save this hose, as you will need it later on.*
5. Remove the upper radiator hose by popping the wire clip out and pulling the hose straight out.
6. Remove the driver side battery and battery tray by removing the four bolts. The degas bottle is attached to the battery tray so be sure to disconnect all coolant lines going to the degas bottle as well as the vacuum line running to the battery tray.
7. Disconnect the electrical connector at the top of the vertical cooler followed by the band clamps that hold it in place, as well as the nut and bolt that hold the top of the cooler.
8. Loosen the clamp on the intercooler tube and pull the tube out of the boot. *It is not necessary to remove the entire intercooler tube.*
9. Disconnect the two coolers from each other by removing the two nuts on the back of the flange and prying the two flanges apart.
10. Hold the intercooler tube back while pulling the cooler up and out. You may need to try rotating the cooler to get it out of the mount.
11. Remove the plastic coolant “Y”. It is brittle so be careful when removing it.
12. Remove the upper radiator hose from the thermostat housing. *If the upper radiator hose is the old version with the single o-ring, you should replace it with the new double o-ring version.* The older version is all black, where as the new version has a whit e end that goes to the thermostat housing.
13. Remove the upper EGR cooler mount. There are three head bolts, and one head stud. *Be sure to keep the stud, as you will need it later on to secure the power steering line.*
14. Remove the nut that secures the dipstick tube in place. Do not discard nut.
15. Remove the steering shaft bolt and slide the stem up and off of the steering box side. Be sure not to turn the steering wheel or tires.
16. Loosen and remove the nuts on the band clamps that hold the lower egr cooler in place. In some cases it may be easier to get them through the wheel well.
17. Remove the rear cooler hose. It may be easier to cut this hose.
18. Remove the two bolts from the rear of the cooler; it is easiest to remove the top bolt from above and the bottom bolt from underneath the truck.
19. Rotate the cooler and pull it forwards to remove it from the bracket. You will need to move the dipstick out of the way to do so.
20. At the front of the coolant line that is attached to the cooler bracket, remove the bolt that holds the coolant tube to the timing cover. *The tube and the cooler bracket will come off in one piece.*
21. Remove the four bolts from the lower cooler bracket.
22. Install the four new exhaust manifold bolts and torque to factory specs.
23. Install the exhaust block off plate using the 2 new bolts and nuts and exhaust gasket
24. Re-install the dipstick hold down nut.
25. Remove the upper cooler hose and steel tube that was attached to the top of the upper cooler and discard.
26. Install the coolant plugs using the factory hardware in place of the lines that came from the cooler.
27. Re-install the stud that was saved from step 12 with the standoff that has been provided then re-install the power steering line support bracket.
28. Re-install the plastic “Y” being careful not to break it.
29. Reconnect the steering shaft and torque to factory specs.
30. Re-install the battery box. Remember to hook up both coolant lines and the small vacuum line.
31. Clean the end of the silicone boot and intercooler tube and re-install.
32. Re-install the upper radiator hose making sure that the metal clips are securely in place.
33. Install the egr block off plate where the top of the upper cooler was attached. *We have supplied two bolts for this plate so that the stud can be remover if you choose to do so.*
34. Use the 3/8” hose that was saved from step 4 to make a piece to reconnect the coolant line to degas bottle and splice it together using the supplied nipple and the existing hose clamps. Use the black routing clips to hold the line in place.
35. Re-route the loose coolant hose on top of the engine back around open coolant port next to the egr block off plate using the factory hose clamps.
36. Fill the truck up with the correct coolant and run the truck checking for leaks. Once the truck reaches operating temperature, top off the coolant.
37. You can see pictures and descriptions of the above install at http://custom-diesel.com/pdf/6.4%20EGR%20Delete%20Kit.pdf

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