Author Topic: EGR Delete (Detailed) (Read 5526 times)

Mitch · « **on:** March 20, 2009, 04:04:52 pm »

This is essentially the component that FireMedic did a DIY on, but more in depth, broken down so there is no frustration and guess work.

(Please pay no attention to my dirty engine. I don't have the time to take care of it cosmetically like I used too.)

As always while working on components with a lot of electrical components, disconnect the batteries.

Next, remove the 4 5/16s bolts holding the shroud on. Next, remove the Dipstick, and pull the shroud off, and replace the dipstick.

Next, with a 7 1/6 deep socket, loosen the 2 clamps on the end of the EGR crossover tube. In the center of the tube, on the bottom, remove the 8mm bolt. Once the tube is removed, remove the 10mm bolts from the dipstick mount.

Here you can see the 8mm bolt that is underneath the EGR crossover tube. To access it, you will need a 1/4 drive ratchet with intention. Push down on the radiator hose to get your ratchet in there.

Next, unplug the EGR (if not already done,) and remove the 4 10mm bolts on the EGR valve. If you do not have replacement gaskets, be careful not to damage the existing gaskets. If you do not have replacement gaskets, I recommend installing your EGR block off plates now, to eliminate the risk of damaging the gaskets.

Next, unplug all wiring connections on the intake horn. I found it easier to remove them after the intake horn was removed. Loosen the clamp holding the boot to the intake horn. Using a small screwdriver, scrape around the entire boot to unstick it from the horn. Remove the boot. Remove the 5 10mm bolts on the intake horn. There are a total of 6, but the 6th bolt also holds on the dipstick bracket. Once all the bolts are out. Carefully remove the intake horn from the heater grid. Careful not to take the gasket with it.

Here you can see what is going in your engine. It looks like your exhaust SHOULD look like. What you are seeing is the heater grid, covered in SOOT.

Next step is to remove the butterfly plate from the intake. This is a #15 torx screw. Close the butterfly, and remove the 2 screws holding the plate on. I have heard these break easily. So be careful.

If you do not have new gaskets, skip this step. I removed the old gaskets from the EGR valve mount.

These are the Gaskets you will need to to replace the existing gaskets.

Place the new gaskets on the intake, and place your block off plates, or in my case, plate, on the gaskets. Install your hardware, making sure the gaskets did not move on you.

Next step is to install the block off plate coming from the EGR cooler.

At this point, you are 1/2 way there. Reinstall in reverse order.

Install the intake horn back on the engine.
Reinstall 5bolts, intake boot, and all wiring connections that you removed from the intake. Zip tie the EGR harness out of the way. This will no longer be used.

Reinstall the dipstick hardware.

I left the Shroud off.

Here is the finished product.

Reconnect batteries, and you are done.

ChinookFE · « **Reply #1 on:** March 20, 2009, 04:21:20 pm »

Looks Good Mitch, Glad to see you back...Do you just leave the other end open like that?

FroneDaddy · « **Reply #2 on:** March 20, 2009, 04:29:48 pm »

Nice write up

Is the EGR part of the new emissions on the 6.7's?

Is that your

lady friend

with the lovely nails on the side of your engine compartment.

Cumminalong · « **Reply #3 on:** March 20, 2009, 04:30:11 pm »

Good looking write-up!

Quote from: ChinookFE on March 20, 2009, 04:21:20 pm

Looks Good Mitch, Glad to see you back...Do you just leave the other end open like that?

There's a black plate there, it just looks open.

Mitch · « **Reply #4 on:** March 20, 2009, 05:39:53 pm »

Quote from: FroneDaddy on March 20, 2009, 04:29:48 pm

Nice write up

Is the EGR part of the new emissions on the 6.7's?

Is that your lady friend with the lovely nails on the side of your engine compartment.

Yes, that is my wife. She has helped me do just about everything, expect the exhaust and headlights.
And yes, the EGR is part of the new emissions junk. Most people have it unplugged, as I did. But I wanted to remove it all together for the full gain. The pressure from the exhaust still leaks through the valve when it is just unplugged. I "should" see another mileage gain.

Next is the EGR cooler delete. That is the big ugly thing that is to the left in all the pics. There is no performance gain, it is merely weight and space.

Mitch · « **Reply #5 on:** March 20, 2009, 05:44:29 pm »

Quote from: Cumminalong on March 20, 2009, 04:30:11 pm

Good looking write-up!

Quote from: ChinookFE on March 20, 2009, 04:21:20 pm
Looks Good Mitch, Glad to see you back...Do you just leave the other end open like that?

There's a black plate there, it just looks open.

Is this worthy of shade tree or contributor?

lilfroger · « **Reply #6 on:** March 20, 2009, 05:52:16 pm »

Those awards are nominated and agreed upon by the Tech / Shade Tree certified group. No need to ask...when they see the kind of write-ups and good solid technical posts they will get together and make it happen.