Detailed EGR Delete Installation for Duramax L5P Owners

Comprehensive Installation Guide for SPETUNER EGR Valve Cooler Delete Kit (2017+ 6.6L Duramax L5P)

Written by Lars, SPETUNER Diesel Modification Specialist

Introduction

Upgrading your 6.6L Duramax L5P with the SPETUNER EGR Valve Cooler Delete Kit is a transformative step toward unlocking better performance and reliability. This guide is designed for DIY enthusiasts who want to take on the installation with confidence. Every step is laid out in detail to ensure a smooth process while highlighting key safety points and tips to optimize your success.

Important Note on Legal Compliance

This EGR Delete Kit is intended for off-road use only. Before proceeding, ensure you understand and comply with the emission laws in your region. Installing this kit on vehicles intended for road use may violate local regulations.

Tools You’ll Need

• Ratchet set (13mm, 15mm, 10mm sockets)
• 1/4" and 1/2" torque wrenches
• Universal joints and extensions
• Flathead screwdriver and pry bar
• Coolant drain pan
• Pliers and hose removal tools

Preparation Checklist:

• Ensure the vehicle is on a stable, level surface.
• Disconnect the battery for safety.
• Have a clean, organized workspace with all tools and parts ready.

Step-by-Step Installation

Part 1: Preparation

Disconnect the Batteries

Start by disconnecting the negative terminals of both batteries. This is a critical safety step to prevent any electrical mishaps.

Remove the Passenger-Side Fender Liner

Use a socket wrench to remove the inner fender liner. This opens up access to key components for the installation process.

Drain the Coolant

Locate the radiator’s drain plug on the lower passenger side. Slowly loosen the plug to let the coolant drain into a pan. Leave the coolant tank cap on to control the flow and minimize splashing.

Part 2: Disassembly

1. Remove the Intake System

• Disconnect and remove the intake pipe and airbox. These components obstruct access to the EGR and related components.

2. Remove the EGR Hot-Side Pipe

• Unscrew the six 13mm bolts holding the hot-side pipe. Remove the heat shield and the pipe connecting the EGR cooler to the Y-bridge.

3. Remove the Turbocharger Intake Horn and PCV Hose

• Using a 13mm universal joint socket and a long extension, remove the two bolts securing the intake horn.
• Gently pry off the PCV hose from the intake horn using a flathead screwdriver.

4. Disconnect and Remove the Y-Bridge

• Detach the wire harness on top of the Y-bridge, including all Christmas tree clips and connectors.
• Loosen the belt tensioner and remove the serpentine belt from the air conditioning (AC) compressor.
• Use a 10mm socket to remove the eight bolts securing the Y-bridge to the intake runners. Carefully remove the bridge, ensuring no debris enters the intake ports. Cover the ports with clean shop rags.

5. Remove the Lower EGR Assembly

• Detach the short hot-side EGR pipe and associated coolant lines.
• Remove the lower EGR valve using a 13mm socket. Install the included manifold block-off plate using two original bolts and torque to 25 ft-lbs.

6. Remove the Turbocharger and SCR System

• Disconnect all coolant and oil lines around the turbocharger.
• Remove the four 15mm bolts securing the turbo to its pedestal and carefully lift it out.
• Detach the SCR assembly and exhaust pipes connected to the turbo.

Part 3: Installation

1. Install Coolant Lines and Block-Off Plugs

• Replace the factory coolant hardlines with the included 20-inch soft hose. Use the provided clamps to secure the connections.
• Install the billet block-off plugs on any unused coolant ports.

2. Reinstall the Turbocharger and Downpipe

• Install the new pedestal gasket and mount the turbocharger back onto the pedestal. Tighten the four mounting bolts to 43 ft-lbs.
• Attach the new downpipe, aligning it with the turbo outlet. Tighten all brackets and clamps to ensure a snug fit.

3. Reinstall the Y-Bridge and Intake Components

• Remove the rags from the intake ports and reinstall the Y-bridge using the original bolts. Torque them to 89 inch-lbs.
• Reconnect the intake horn, PCV hose, and airbox.

4. Finalize Coolant System Connections

• Replace any remaining coolant hoses and refill the radiator with fresh coolant.

Part 4: Testing and Adjustments

Check for Leaks

Start the vehicle and let it idle. Inspect all connections for coolant or air leaks. Tighten clamps as necessary.

Bleed the Coolant System

Allow the engine to cycle through its heating and cooling phases. Top off the coolant as the system purges air pockets.

Verify Performance

Test the vehicle’s acceleration and monitor turbo responsiveness. Ensure all systems are functioning as expected.

FAQ

Q: How long does installation take?
A: Installation typically takes 4-6 hours, depending on your experience level and access to tools.

Q: Will this void my vehicle warranty?
A: EGR delete modifications may void certain warranties. Consult your dealer for more information.

Q: Do I need special tools?
A: Standard tools are sufficient, but a torque wrench and universal joint sockets are essential for this installation.

Conclusion

Installing the SPETUNER EGR Valve Cooler Delete Kit is a rewarding upgrade that boosts your Duramax’s performance and reliability. This guide provides a detailed roadmap to help you navigate the process confidently. Should you encounter any issues, SPETUNER’s support team is always ready to assist.

Get ready to enjoy a cleaner, more powerful driving experience!