Installation Guide for 6.0L Powerstroke EGR Delete Kit

Author: Lars, SPETUNER Diesel Modification Specialist

Introduction: A Word on Compliance

Before diving into the installation process, let’s address a critical point—this kit is designed for off-road use only. It’s essential to ensure your vehicle’s intended use complies with local emissions regulations. Always check the laws in your area and consult a professional if you’re unsure.

Now, let’s get started!

Preparation: Setting Yourself Up for Success

Tools You’ll Need

• Basic Tools:Socket set, screwdrivers, torque wrench
• Specialized Tools:V-band clamp tool, small pry bar
• Penetrating Oil:For loosening older bolts
• Containers:To drain and hold coolant
• Cleaning Supplies:Compressed air, rags

Parts Checklist

Before starting, double-check the parts you received against the provided list. This ensures you have everything needed to complete the job, including the EGR block-off plate, stainless steel coolant pipe, and silicone hoses. Missing something? Contact SPETUNER support before proceeding.

Work Area Prep

• Make sure the engine is cool before working.
• Lay out all tools and parts in an organized fashion to avoid fumbling mid-installation.
• Use a dust cover to keep debris out of sensitive areas like the intake manifold.

Step-by-Step Installation Guide

Step 1: Disconnect and Drain

1. Disconnect the negative battery terminals to eliminate any risk of electrical mishaps.
2. Drain the coolant into a clean container for proper disposal or reuse.

Step 2: Remove Existing Components

1. Wire Harness Channel:Remove the plastic wire harness clips and fold the harness toward the windshield.
2. Fan Shroud:Pry the upper fan shroud loose using the designated slots on the radiator.
3. Intake Tubes:Loosen the hose clamps and remove the intake tube, turbo inlet pipe, and PCV valve. Blow compressed air through the intake openings to clean any debris.
4. Charge Pipe & Alternator:Loosen the clamps on the charge pipe, then unbolt and tilt the alternator forward without touching the belt tensioner.

Step 3: Turbocharger Removal

1. Disconnect Downpipe:Remove the V-band clamp securing the downpipe to the turbo and the two bolts connecting the catalytic converter.
2. Remove Turbocharger:Disconnect the oil feed lines, VGT actuator wire, up-pipe clamps, and mounting bolts.

Tip: Apply penetrating oil to stubborn bolts to avoid stripping them.

3. Remove the turbo pedestal and the oil drain tube from the HPOP cover.

Step 4: Remove EGR Cooler and Intake Manifold

1. Loosen the intake manifold bolts on the driver’s side but leave them in place. Fully remove the bolts on the passenger side and use a piece of cardboard to mark their positions for reinstallation.
2. Remove the EGR cooler’s three mounting bolts. Use a small pry bar to gently shift the cooler backward while lifting the intake manifold.
3. Lift the cooler out through the front of the engine bay. Ensure all gaskets and O-rings are removed.

Step 5: Install SPETUNER Components

1. EGR Block-Off Plate:Install the provided block-off plate onto the up-pipe using the existing V-band clamp.
2. Reinstall Intake Manifold:Position the manifold back in place, reinsert all bolts, and torque them to 120 in-lbs.
3. Install Coolant Components:Attach the supplied stainless steel coolant pipe, silicone hoses, and hose clamps. Keep the clamps loose initially for easy adjustment.
4. Adapter Installation:Grease the O-ring on the SPETUNER billet adapter, place it into the intake manifold opening, and finger-tighten the bolts. Ensure the adapter aligns perfectly before tightening to 120 in-lbs.

Step 6: Reassembly and Testing

1. Reinstall all components in reverse order, including the turbocharger, intake and exhaust tubes, alternator, and wiring harness.
2. Refill the coolant system with a manufacturer-recommended coolant mixture.
3. Start the engine and let it run until the coolant circulates. Check for leaks at all connection points.

Post-Installation Checklist

• Inspect Seals:Ensure there are no oil or coolant leaks.
• Test Fit:Verify all components are securely fastened and aligned.
• Final Coolant Check:Top off the coolant system to the correct level after a short engine run.

Final Thoughts from Lars

By following this guide, you’ve just enhanced your Powerstroke’s reliability and performance for off-road adventures. If you run into any challenges during the installation, don’t hesitate to reach out to SPETUNER’s support team. We’re here to help.

Enjoy your upgraded ride, and remember—always keep it legal and safe!

FAQs for SPETUNER 6.0L Powerstroke EGR & Cooler Delete Kit

Q1: Can you delete the EGR on a 6.0 Powerstroke?
A1: Yes, you can delete the EGR on a 6.0 Powerstroke using an EGR delete kit designed specifically for this purpose. However, it’s essential to ensure your vehicle is used for off-road purposes only and complies with local regulations.

Q2: Do you gain HP from an EGR delete?
A2: Yes, an EGR delete can improve horsepower and torque by reducing exhaust gas recirculation and increasing airflow. The exact gains depend on additional modifications and ECU tuning.

Q3: How illegal is an EGR delete?
A3: In most regions, EGR deletes are not legal for vehicles used on public roads as they bypass emissions controls. Off-road use is typically permitted, but always check local laws to avoid fines or penalties.

Q4: Is the EGR delete kit worth it?
A4: For off-road enthusiasts, an EGR delete kit is worth it as it improves engine reliability, reduces soot buildup, and enhances performance. However, it’s crucial to weigh the legal and environmental considerations.

Q5: Will deleting the EGR affect fuel economy?
A5: An EGR delete often improves fuel economy, especially for vehicles frequently used in heavy-duty or off-road conditions, as it optimizes combustion efficiency.

Q6: Do I need to tune my ECU after an EGR delete?
A6: Yes, tuning your ECU after an EGR delete is highly recommended to avoid engine error codes and ensure optimal performance.

Q7: What tools are required for installing an EGR delete kit?
A7: Basic tools like a socket set, screwdrivers, torque wrench, and specialized tools such as a V-band clamp tool and pry bar are needed for a proper installation.

Q8: Does an EGR delete reduce maintenance costs?
A8: Yes, deleting the EGR can reduce maintenance costs by preventing carbon buildup in the intake system and eliminating the need for EGR cooler replacements.

Q9: How long does it take to install an EGR delete kit?
A9: The installation process typically takes 4-6 hours, depending on your experience and tools available.

Q10: Are there alternatives to an EGR delete?
A10: Alternatives include using upgraded EGR coolers or cleaning the EGR system regularly, which maintain emissions compliance while addressing reliability concerns.

Upgrade Your 6.0L Powerstroke with SPETUNER EGR Delete Kit Today!