XDP Duramax LBZ EGR Race Track Kit Item Number: XD165 PACKING LIST: 1 LBZ EGR Plate for Up Pipe 5 M8x1.25-20mm Bolt 2 M10x1.5 Flange Hex Nut 1 LBZ EGR Plate for Intake 1 M8x1.25-45mm Bolt 1 M8x1.25 Flange Hex Nut 1 - EGR blocker support plate 1 M10x1.25-20mm Bolt 3 EGR Gaskets 1 Standoff A 2 - M6x1.0-25mm Bolts 1 20" 5/8" Heater Hose 1 Standoff B 1 M10x1.5-80mm Stud 2 5/8" Hose Clamps 1 Standoff C 1 M10x1.5-95mm Stud Before removing any parts from your truck, please compare the items you have received with the packing list provided to verify that you have everything necessary to install your XDP Duramax LBZ EGR Race Track Kit. WARNING: This high performance product is intended SOLELY for closed-course racing use and is not street legal in ANY state. This product cannot be used on any vehicle that is registered or certified for highway use. *Aftermarket Tuning Required* Ensure that the vehicle has not been in use and that the engine is cool to the touch. Always wear eye protection when working on any vehicle. * PLEASE READ INSTRUCTIONS PRIOR TO INSTALLATION * XDP Duramax LBZ EGR Race Track Kit (XD165) Page 1
XDP Duramax LBZ EGR Race Track Kit Step 1: Disconnect negative battery cables. Step 2: Remove passenger side inner fender. Step 3: Remove coolant tank cap. Step 4: Locate the lower radiator hose on the passenger side of the radiator. Step 5: Remove the butterfly clip. Step 6: Place a drain pan under the passenger side of the radiator. Step 7: Gently pull the radiator hose back to drain. (The coolant will drain quickly.) Intake Tube Step 8: Remove the resonator and intake tube. Step 9: Remove the (3) wiring harness retaining bolts on top of the intake bridge using a T30 tork drive. Step 10: Remove the (2) bolts retaining the cast aluminum CAC pipe. Bolt 1 Resonator Bolt 2 XDP Duramax LBZ EGR Race Track Kit (XD165) Page 2
Step 11: Remove the bolt retaining the dipstick tube. Step 12: Remove the ignition wire for the intake air heater. Step 13: Disconnect the MAF sensor connector. Step 14: Remove the EGR actuator connector on the passenger side of the truck. XDP Duramax LBZ EGR Race Track Kit (XD165) Page 3
Step 15: Remove the butterfly clip retaining the cast aluminum CAC pipe and the plastic CAC pipe together. Step 16: Remove the wiring harness bracket connected to the stud on the intake horn by removing the nut with a 12mm socket. Step 17: Gently pull the wiring harness towards the front of the truck. Step 18: Remove the bolt holding down the PCV hose to the valve cover on the passenger side of the motor with a 10mm socket. XDP Duramax LBZ EGR Race Track Kit (XD165) Page 4
Step 19: Use needle nose pliers to remove the spring clamp on the turbo intake. Lay the PCV hoses over to the driver side of the truck. Step 20: Remove the turbo vane actuator solenoid connector and set aside. Step 21: Loosen the band clamp on the turbo intake mouthpiece and remove XDP Duramax LBZ EGR Race Track Kit (XD165) Page 5
Step 22: Remove the (4) bolts retaining the intake bridge. Set the intake bridge aside. Step 23: Remove the heater core coolant hose that is closest to the driver side of the truck. Step 24: Remove the two nuts retaining the EGR cooler to the uppipe. Nuts are removed from the back of this flange Step 25: Remove the two bolts retaining the EGR cooler to the EGR cooler bracket. Bolts retain the cooler in this bracket XDP Duramax LBZ EGR Race Track Kit (XD165) Page 6
Step 26: Using a 14mm socket remove the two bolts on the front of the EGR cooler and remove the cooler. Step 27: Clean the up-pipe sealing surface to ensure a proper seal. Step 28: Install the up -pipe blocker plate and gasket. Use one M8x1.25-20mm bolt for the upper blocker plate hole, and use the M8x1.25-45mm bolt for the lower blocker plate bolt. (Make sure you tighten these two bolts before moving to the next step) Step 29: Remove the two bolts on the EGR bracket that are retaining the heat shield above the Rail Pressure Sensor. Step 30: Install the EGR blocker support plate provided with your kit using the two M6x1.0-25mm bolts. Step31: Finger tighten the M8x1.25 nut onto the M8x1.25-45mm bolt and the M10 bolt that retains the up -pipe blocker plate to the EGR cooler bracket. Once both installed they can then be tightened each with a wrench. Step 32: Install the heater hose on the two open coolant ports and secure with supplied hose clamps. Step 28 Step 29 Photo shows an LMM plate Step 30 XDP Duramax LBZ EGR Race Track Kit (XD165) Page 7
Step 33: Set standoff A in the mounting location of the EGR actuator closest to the alternator. Step 34: Set the wiring harness ring terminal on top of standoff A. Step 35: Install the 95mm stud through the wiring harness ring terminal and standoff A. Step 36: Install standoff B on the 90mm stud. Step 37: Install the 80mm stud in the outer most bolt hole that previously retained the EGR motor. Step 38: Install standoff C on this stud. Standoff A Standoff C Standoff B Wiring harness ring terminal Step 39: Install the intake bridge bracket with the long straight edge toward the front of the truck and the laser engraving facing down. Step 40: Retain the intake bridge with the two M10 flange head nuts. (Do not tighten the flange head nuts yet.) Step 41: Clean the sealing surface of the intake bridge. Step 42: Lay the intake bridge gaskets in their appropriate location on the intake bridge support plate. Step 43: Install the intake bridge on the intake horn and support plate. Fasten the intake bridge to the support plate using (4) M8x1.25-20mm flange head bolts and use factory fasteners to refasten the intake bridge to the intake horn. Step 44: Tighten the two M10 flange head nuts on the studs. XDP Duramax LBZ EGR Race Track Kit (XD165) Page 8
Step 45: Reinstall the cast aluminum CAC pipe and retaining bolts. Step 46: Reinstall the turbo intake mouthpiece. Do not tighten. Step 47: Reinstall the PCV on the passenger side valve cover and into the intake mouthpiece. Step 48: Reinstall the turbo vane actuator solenoid connector. Step 49: Reinstall the intake pipe from the mouthpiece to the air filter box. Tighten both ends then tighten the mouthpiece. Step 50: Reinstall the resonator and PCV tube. Step 51: Ensure the radiator drain plug is closed and refill the cooling system with coolant. Step 52: Connect the battery cables. Step 53: Start the truck and check for leaks. Step 54: Drive the truck to further check for coolant leaks and check for drive pressure leaks. (A drive pressure leak will create a squealing sound.) PLEASE CONTACT XDP (1-888-343-7354) FOR TECHNICAL ASSISTANCE XDP Duramax LBZ EGR Race Track Kit (XD165) Page 9