// Install guides
EGR DELETE — 08-10 POWERSTROKE 6.4L
Never work on a hot vehicle. Allow it to cool before starting, and wear eye protection when working on or under it. Not legal for sale or use on pollution-controlled motor vehicles anywhere in the United States. Legal only for off-road competition racing vehicles that are not operated on public streets, roads or highways. By installing this product you assume all risk and liability for its use, and it is your responsibility to make sure your vehicle complies with all federal, state and local emissions laws. It may also void the manufacturer's warranty.
Removing both EGR coolers and the EGR valve on a 2008–2010 Ford F-250/F-350 Super Duty 6.4L Power Stroke and fitting the cooler delete kit. Kit contents: A. Coated intake elbow B. Blocker plate gasket C. Exhaust blocker plate D. M10-1.25 x 40 manifold bolts (x4) E. Coolant plug with O-ring (x2) F. M10-1.125 x 20 plate bolts (x2) G. M6-1.25 x 25 intake elbow bolts (x4) H. Hose routing clips (x2) I. Plug bolts (x2) J. Intake elbow O-ring K. Stud spacer L. Barbed hose connection
Steps
1 Keeping the EGR cooler?
If you are running emissions-off tuning but leaving the cooler in place, unplug the two EGR connectors on the front of the engine near the fan shroud so the truck throws no warning codes. Those two plugs are the only ones that need to come off.
2 Make sure the front wheels are straight
3 Disconnect both batteries
The drain plug is on the bottom of the radiator on the driver side.
4 Drain the coolant
The drain plug is on the bottom of the radiator on the driver side.
5 Remove the 3/8" hose that runs to the degas bottle
The degas bottle is the coolant overflow tank. Keep this hose: it is reused during installation.
6 Remove the upper radiator hose
Pop the wire clip out and pull the hose straight out.
7 Remove the driver side battery
Also remove the vent line going to the battery tray.
8 Remove all coolant hoses going to the degas bottle
Also remove the vent line going to the battery tray.
9 Remove the battery tray and degas bottle
Held on by four bolts.
10 Separate the driver side intercooler tube from its rubber boot
Loosen the clamp on the tube. It is not necessary to remove the tube.
11 Disconnect the electrical connector on top of the vertical EGR cooler
Remove the nuts and bolts securing the coolers together. Release the mounting clamps and separate the two coolers by prying on the flanges.
12 Disconnect the vertical EGR cooler's coolant lines and separate the two coolers
Remove the nuts and bolts securing the coolers together. Release the mounting clamps and separate the two coolers by prying on the flanges.
13 Pull the vertical EGR cooler up and out
Hold the intercooler tube back while you do. You may have to rotate the cooler to release it from its mount.
14 Remove the plastic coolant tube
Be careful not to break it: it is reused during installation.
15 Remove the upper radiator hose from the thermostat housing
If your radiator hose has a single O-ring, it is a good idea to replace it with the newer double O-ring version.
16 Remove the upper EGR cooler mount
Use a 10mm wrench for the three bolts and a 13mm wrench for the stud. Keep the stud: it secures the power steering line during the install.
17 Remove the steering shaft bolt and slide the stem up and out of the steering box shaft
Be sure not to turn the steering wheel or the tires.
18 Remove the steering shaft bolt and slide the stem up and out of the steering box shaft
Be sure not to turn the steering wheel or the tires.
19 Release the mounting clamps on the lower EGR cooler
It may be easier to reach the clamps through the wheel well.
20 Remove the coolant line on the lower EGR cooler
It may be easier to cut the line. It will not be reused.
21 Remove the bolts on the rear flange of the EGR cooler
The bottom bolt is easier to reach from underneath the truck, the top bolt from above.
22 Remove the lower EGR cooler
With the dipstick moved out of the way, pull the cooler forward and rotate it out of its mount.
23 Remove the bolt securing the coolant line to the timing cover
This line is attached to the lower EGR cooler mount and comes out with it as one piece.
24 Remove the lower EGR cooler mount
Use a 10mm wrench for the four bolts.
25 Install the four replacement manifold bolts
M10-1.25 x 40, into the exhaust manifold. Torque to factory specification.
26 Install the exhaust block off plate
Use the M10-1.125 x 20 bolts and the gasket.
27 Remount the dipstick tube
Use the factory bolt.
28 Replace the vertical cooler's coolant tube with a supplied coolant plug
Remove the coolant tube that ran from the vertical EGR cooler to the engine, and fit the plug from the kit to block off the hole.
29 Install the second coolant plug
Use the factory bolts that secured the lines.
30 Reinstall the stud with the supplied spacer and secure the power steering line to it
Use a 13mm wrench.
31 Reinstall the plastic coolant tube
Be careful not to crack or break it.
32 Reconnect the steering shaft
Torque to factory specification.
33 Reinstall the battery box and degas bottle
Clean the end of the silicone boot and the intercooler tube with glass cleaner, then reconnect.
34 Clean and reconnect the intercooler tube
Clean the end of the silicone boot and the intercooler tube with glass cleaner, then reconnect.
35 Reconnect the coolant lines to the degas bottle
Also reconnect the vent line to the battery box.
36 Reconnect the upper radiator hose
Make sure the metal clips are securely in place.
37 Disconnect the wire connectors to the EGR valve
Remove the four bolts and loosen the hose clamp on the intercooler plumbing.
38 Remove the EGR valve
Remove the four bolts and loosen the hose clamp on the intercooler plumbing.
39 Install the intake elbow
Slide the tube into the boot, then secure the flange to the intake manifold with the supplied M6-1.25 x 25 bolts.
40 Reconnect the coolant line over the radiator to the degas bottle
Use the 3/8" hose saved from step 4 and the barbed hose connection from the kit. Cut the line to length and reuse the factory hose clamps.
41 Reconnect the coolant line over the radiator to the degas bottle
Use the 3/8" hose saved from step 4 and the barbed hose connection from the kit. Cut the line to length and reuse the factory hose clamps.
42 Refill the coolant
To factory specification.