-888-628-1730 1-888-628-1730 • Black• Maxx www.hsperformance.
INTRODUCTION Warning! This high performance product is intended for off-road, closed-course racing use ONLY. This product may never be installed on a vehicle registered for highway use. By installing the EGR or EGR Cooler Delete Kit onto your vehicle, you assume all risk and liability associated with its use. It is your responsibility to ensure that your vehicle complies with all national, state, and local emissions laws.
KIT CONTENTS • • • • • • • • • • • • One Exhaust Manifold Block-off Plate One Intake Block-off Plate One Coolant Block-off Plate One 1” Hose Clamp One Straight Barbed Fitting One Vacuum Cap One Pressure Sensor Bracket One Pressure Sensor Bracket Hardware Two 3/4” Coolant Caps Three 8mm Bolts Three 8mm Washers Three Zip-Ties Removed parts Pictured above are the major components that will be removed from the vehicle during this installation guide. 1-888-628-1730 • www.hsperformance.
STEP 1 Drain coolant from both coolant systems. Remove caps from both radiator overflow tanks. The drain for the cold coolant system is found on the passenger side and the drain for the hot coolant system is found on the driver side. Drain about 3 gallons from the hot system and about 2 gallons from the cold system. You may need to use multiple buckets. After draining, close both drain plugs. STEP 2 Disconnect the negative terminals from both batteries using an 8mm wrench. 4 Ford 6.
STEP 3 Unplug the MAF sensor located on the air intake. The red locking tab will need to be pulled out before harness can be unplugged. Unclip the MAF sensor wire harness from the air box. STEP 4 Remove the two 8mm bolts holding the intake box and air reserve chamber. 1-888-628-1730 • www.hsperformance.
STEP 5 Loosen the two clamps located on intake system. STEP 6 Pull up firmly on air box to dislodge it from lower rubber mounts. Slide coupling off of the air box and remove it from the vehicle. 6 Ford 6.
STEP 7 Dislodge the three coolant lines attached to the remaining portion of the air intake and remove the remaining portion of the air intake from the vehicle. 1-888-628-1730 • www.hsperformance.
STEP 8 Disconnect clips and brackets holding the two larger coolant lines. Using pliers from the top of the vehicle, loosen the three factory clamps on larger coolant lines and pull lines off of connections. Using a long flathead screwdriver from the bottom of the vehicle, pry remaining coolant line end away from radiator as much as possible while someone else pulls firmly on coolant line from above to disconnect from radiator. Remove both coolant lines from vehicle. 8 Ford 6.
STEP 9 Remove the two permanent clamps on the small coolant line tee shown below. Install supplied straight barbed fitting, eliminating the line that goes to the EGR system. 1-888-628-1730 • www.hsperformance.
STEP 10 Using the factory clamp, install a supplied 3/4” cap onto cold coolant system reservoir. From the top of the truck, slide the other supplied 3/4” cap and supplied hose clamp onto the cold coolant system radiator. Using a long flathead screwdriver, tighten clamp from underneath vehicle. 10 Ford 6.
STEP 11 Disconnect the snap-fitted coolant line from the metal coolant pipe. Press tabs on both sides of fitting and slide off. Tuck line away from EGR system. STEP 12 Unplug harness from temperature sensor in EGR piping. Zip-Tie remaining harness out of the way of moving/hot parts. 1-888-628-1730 • www.hsperformance.
STEP 13 Unplug harnesses from the Powertrain Control Module (PCM) located on the passenger side firewall. Tuck harnesses away from EGR system. STEP 14 Unplug the three harnesses located on top of the EGR cooler. The orange harness has a yellow lock tab that must be slid out before the harness can be unplugged. The black harness has a metal locking clip that must be pried out before the harness can be unplugged. Re-install the metal locking clip after unplugging to prevent losing the small clip. 12 Ford 6.
STEP 15 Unplug vacuum line from EGR system. Remove 90 degree end from vacuum line and install supplied vacuum cap. STEP 16 Unplug the EGR Butterfly Valve located near the radiator fan shroud. 1-888-628-1730 • www.hsperformance.
STEP 17 Remove two bolts holding wiring harness to front of EGR cooler. STEP 18 Remove two clips holding black fire retardant heat shield to passenger side of EGR cooler. 14 Ford 6.
STEP 19 Remove the four 8mm bolts from the short EGR pipe and remove the short EGR pipe from vehicle. Retain bolts and gaskets for later use. STEP 20 Remove the two 8mm bolts from the bracket holding the long EGR pipe to the EGR cooler. Remove the four remaining 8mm bolts from the long EGR pipe and remove the long EGR pipe from vehicle. Retain bolts and gaskets for later use. 1-888-628-1730 • www.hsperformance.
STEP 21 Remove the seven 8mm bolts holding the EGR system to the passenger side intake manifold. Remove the 10mm nut holding the pressure line bracket to the back side of the EGR cooler. STEP 22 Pull the EGR system towards the front of the truck. You may need to twist the EGR system slightly counter-clockwise in order to clear the black intake “Y”.
STEP 23 Reconnect PCM harnesses to PCM, ensure you have a good connection. Zip tie unused EGR harnesses and vacuum line to PCM harness. STEP 24 Reconnect the coolant line with the snap fitting, ensure the line “clicks” in. 1-888-628-1730 • www.hsperformance.
STEP 25 Using previously removed hardware and gasket, install the supplied exhaust manifold block-off plate (smallest plate). Tighten. STEP 26 Using previously removed hardware and gasket, install the supplied intake block-off plate (medium sized plate). Tighten. 18 Ford 6.
STEP 27 Slide the three supplied 8mm washers onto the three supplied 8mm bolts. Using the hardware, install the coolant block-off plate (largest plate). Tighten. STEP 28 Remove the rear-left (passenger side closest to the firewall) bolt on the black intake “Y”. Using factory bolt, loosely install supplied Pressure Sensor Bracket. Using supplied small bolt, washers, and nut, bolt previously installed bracket to the pressure line hook-bracket. Tighten all hardware. 1-888-628-1730 • www.hsperformance.
STEP 29 Reinstall intake system. Reconnect MAF sensor. If the small coolant line is long enough, route line through old routing tabs on intake system. STEP 30 Reconnect batteries. Refill coolant systems. Start the vehicle and ensure there are no leaks present. Burp coolant systems and add coolant as necessary. 20 Ford 6.
WARRANTY & DISCLAIMER All EGR Kits are considered high performance racing parts, and are intended and developed for non-street-legal, off-highway, closed course racing use ONLY! Installation of this product on a non-sanctioned race vehicle, on ANY road, public or private, is STRICTLY PROHIBITED in the United States and Canada.
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Hard parts H&S offers many performance parts for late model diesel trucks. Please visit our online store to see what we have to fit your truck. Exhaust Products H&S Performance carries a full line of mandrel bent exhaust. Whether you desire 4” or 5” we have a kit to suit your needs. We also carry a full selection of stainless tips to finish it off with some style. H&S Newsletter • Monthly Product Updates • Monthly Tech Tips • New Web Site Features • And More! Visit www.hsperformance.
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