EGR Cooler Delete Kit

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1 EGR Cooler Delete Kit Liter Ford

2 ATTENTION!!!! The Street Diesel Performance Egr Cooler Delete System kits are designed to be used in conjunction with proper tuning and supporting hardware such as an EGR removal kit. If steps are not taken to ensure proper install and operation of this kit serious engine damage may occurr. TROUBLESHOOTING: Please read and understand all install instructions before proceeding with the installation. If you have questions during the installation of this product, Street Diesel Performance

3 STEP 1 Allow the motor to completley cool off prior to removal of existing parts and install of this product. Center the steering system, disconnect the battery(s), and drain the coolant system. STEP 2 Remove 3/8 inch hose that runs from top EGR cooler to the coolant reservoir. This hose is no longer needed. STEP 3 Remove the upper radiator hose clip (radiator side) and pull hose free from radiator. STEP 4 Remove the driver s side battery, battery tray, and degas bottle assembly. Be careful of the vacuum line that attaches to the bottom of the battery tray. This will need to remain intact. STEP 5 Remove the band clamp support nuts, disconnect the EGR cooler sensor plug, and remove the hose clamps that hold the feed/return hoses to the upper/vertical cooler. STEP 6 Disconnect the hot side intercooler pipe from the turbo outlet. There is no need to completely remove the pipe assembly; it only needs to be removed from this end to allow for movement.

4 STEP 7 Remove the two nuts that hold the upper/vertical cooler to the lower/horizontal cooler at the flex elbow. Remove the hoses from the upper/vertical cooler. STEP 8 Twist the upper/vertical cooler while gently prying the connector flange from the lower/horizontal cooler. While holding the hot side intercooler pipe aside maneuver the vertical cooler away from the engine and remove. STEP 9 Once the factory elbow is removed be careful not to damage the O-ring that is seals the elbow to the intake manifold. The o-ring will need to be removed and reused in the adapter plate that comes in the CFM intake elbow kit. See illustration below. Be sure to inspect the o-ring for any damage before installing it into the CFM adapter plate. Thoroughly clean the mating surface of the intake manifold. STEP 10 Below the previous location of the upper/vertical cooler is a plastic Y shaped coolant pipe. This piece is VERY BRITTLE and is to be removed to prevent breakage. This will be reinstalled later. STEP 11 Remvoe the cast iron upper cooler bracket from the front of the motor. There are three 10mm headed bolts and one 13mm nut on a stud. Save the stud as this will need to be used later to secure the power steering hose. Remove the second (lower) bracket that held the lower portion of the upper/vertical cooler. Remove the oil dipstick hold down nut. STEP 12 Remove the steering shaft bolt and slide the two parts away from each other. You may want to mark the two shafts to insure proper realignment upon reassembly should you suspect the steering might be inadvertently moved.

5 STEP 13 Loosen and remove the nuts that secure the lower/horizontal hold down bands. This may be easier accomplished via the driver side wheelwell. Remove or cut the coolant hose that attaches to the side of the lower/horizontal cooler. Remove the two bolts that attache the lower/horizontal cooler to the exaust feed piping. One of the bolts is easier accesed from the bottom of the truck. Maneuver the cooler to clear the oil dipstick tube and push the dipstick tube to the right (drivers side) of the steering shaft. STEP 14 Pull the cooler up and out towards the front of the vehicle. Remove the coolant hose/metal tube that is attached to the cooler bracket. As an optional step you can remove the four 10mm head bolts that secure the bracket to the exaust manifold and remove the bracket. If you choose to do this you will need to purchase shorter bolts to replace the OEM ones. STEP 15 Reinstall the oil dipstick tube hold down nut after placing the dipstick tube back into its origional location. Remove and discard the coolant hose/steel tube that exits the front cover and previously fed the upper cooler. STEP 16 Install the billet aluminum coolant plugs in the front cover of the water pump assembly. The first plug will be placed where the coolant hose/tube was removed in step 15 (see arrow). The second plug will be placed where the coolant line was removed in step 14. (see arrow)

6 STEP 17 Reinstall the stud that was removed earlier from the front cover earlier and secure the power steering hose to it using the nut. Reinstall the earlier removed plastic Y coolant line. Do not over tighten the bolts. Reconnect the steering shaft and torque to factory specs. Reinstall the battery box assembly not forgetting the vacuum tube located on the bottom of the tray. STEP 18 After thoroughly cleaning the inside of the intercooler boot and the outside of the hot side intercooler pipe reattach the intercooler pipe to the turbo outlet. If oil residue is left on the boot and pipe there is the possibility of the two separating under high boost and scaring the crap out of you. STEP 19 Reinstall the upper radiator hose to the radiator then install the metal retaining clip. Make sure the hose is secure. Attach hoses to the degas bottle taking care to ensure that they are secure. Refill the coolant and run the motor to circulate out any air pockets in the coolant system. Check for leaks. Thank You For Your Purchase

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