// Install guides
EGR DELETE — 20-25 DURAMAX 3.0L LM2
Before starting, fully disconnect both the main and auxiliary batteries (if fitted) to prevent accidental electrical shorts. Then allow the vehicle to cool so the engine, exhaust components and surrounding areas are safe to touch. Arrows in the photos point to the front of the vehicle.
Removing the EGR cooler, valve and crossover pipe on a 2020–2025 Chevy/GMC 1500 3.0L Duramax LM2 and fitting the supplied block off plates. The DPF and catalytic converter come out along the way, so this also covers fitting the 3" turbo back DPF delete pipe. Before beginning, carefully unpack your kit and verify that every component, fastener and accessory listed below is present. Inspect each item to ensure nothing is missing, damaged or incorrectly supplied. Confirming a complete set of parts before you start prevents delays partway through. Kit PD-2-53235000: • 1 x EGR block off plate • 1 x Turbo plate • 1 x Intake plug • 1 x Coolant hose • 1 x Ground cable (pickup applications only) • 3 x Stainless hose clamps (small) • 3 x Stainless hose clamps (large) • 4 x Cable/zip ties • 3 x Barbed hose fittings
Steps
1 Disconnect the batteries and drain the engine coolant
Recover the A/C refrigerant. Remove the passenger side fender liner.
2 Remove the oil filler cap and plastic intake manifold cover
Reinstall the oil filler cap once the intake manifold cover is off, to prevent debris falling into the engine.
3 Remove the battery tie down
Remove the 2 bolts holding the battery tie down, then remove the tie down. Then remove the power distribution box cover.
4 Unplug the fuse block connections
Remove the nut holding the positive terminal to the fuse block. Remove the electrical connector (highlighted green), then remove the 6 nuts on the circled connections and unplug them. Unplug the two center connections as well. All connectors are labeled to ensure they are reinstalled properly.
5 Remove the power distribution block
Undo the locking tabs on the power distribution block and remove it.
6 Remove the battery retainer
Remove the battery hold down bolt, then remove the battery retainer.
7 Remove the battery and the fuse box cover
8 Unbolt the fuse box
Remove the 4 bolts holding the fuse box down to the pictured connectors. There are 4 retaining tabs that need to be unclipped after slightly loosening the bolts first.
Do not use power tools for this step. Remove the bolts slowly and evenly.
9 Remove the fuse box base
Remove the electrical connectors (previously highlighted in green), remove the two bolts, and remove the fuse box base.
10 Remove the battery tray
Remove the bolts from the battery tray and remove it from the vehicle. Be sure to disconnect anything else that is attached to it.
11 Reposition the A/C lines
Undo the A/C line fasteners. Reposition the upper A/C lines out of the way and remove the bottom lines from the vehicle.
12 Remove the NOx and particulate sensors
Remove the nitrogen oxide sensors and the particulate sensor and move them out of the way. These sensors stay plugged in to their connectors for now.
Remove the exhaust clamp next to the particulate sensor.
13 Remove the catalytic converter
Lower: remove the two nuts holding the front pipe to the support bracket, and the two nuts holding the bracket to the engine block. Remove the bracket.
Upper: remove the two nuts on the flange.
Maneuver the catalytic converter out.
14 Disconnect the exhaust back pressure valve
Disconnect the exhaust back pressure valve electrical connector (highlighted green). Remove the coolant line bolts (highlighted red).
15 Remove the exhaust back pressure valve
Remove the 3 nuts securing the exhaust back pressure valve, then remove the valve.
16 Remove the EGR inlet pipe
Remove the 4 bolts holding the EGR inlet pipe, then remove the pipe.
17 Loosen the EGR cooler hardware
Remove all hardware (highlighted red) and disconnect one electrical connector (highlighted green). Also disconnect the electrical connector (circled green).
Leave the parts in place for now.
18 Remove the two bolts on top of the catalytic converter
19 Remove the EGR cooler
Remove the mounting nuts (highlighted red) and disconnect. Disconnect the two larger coolant hoses (circled green) and the smaller pressure sensor hose (circled blue). Remove the EGR cooler.
20 Undo the EGR pressure sensor hose clamp
21 Remove the EGR cooler valve assembly
Items 8 and 13 in the diagram.
22 Remove the EGT sensor from the turbo
Move it out of the way. This sensor is reinstalled when finished.
23 Remove the turbocharger heat shield
Undo the fasteners and remove the heat shield.
24 Loosen the DPF clamp
This clamp will be reused.
25 Remove the NOx sensor at the DPF
Remove the 2 nuts (highlighted red) and the nitrogen oxide sensor (circled green). Leave it plugged in and set the sensor out of the way.
26 Remove the remaining DPF sensors and the DEF injector
27 Remove the DPF
Remove all hardware (highlighted red) that fastens the DPF down, then remove the DPF. After DPF removal, reinstall the nut from figure A for the coolant hose support bracket.
28 Remove the DPF
Remove all hardware (highlighted red) that fastens the DPF down, then remove the DPF. After DPF removal, reinstall the nut from figure A for the coolant hose support bracket.
29 Remove the coolant crossover assembly
Disconnect the heater core line (circled green), the turbo coolant line (circled blue) and the coolant crossover (circled orange). Undo the clamp (highlighted red). Remove the assembly.
30 Remove the exhaust back pressure sensor assembly
Remove the 2 studs (highlighted red) and the electrical connectors to the exhaust back pressure sensor. Remove the sensor assembly.
31 Remove the air intake duct
32 Remove the bolt from the coolant line support bracket
33 Remove the intake silencer
It sits between the turbo and the charge air cooler.
34 Remove the EGR crossover pipe bolts
Remove the bolts (highlighted red) from the EGR crossover pipe.
35 Free the EGR crossover pipe and harness
Remove the coolant hose clip and remove the bolt from the EGR crossover pipe. Remove the 2 remaining harness retainer nuts and reposition the harness.
36 Remove the EGR crossover pipe
Lift the driver side first. Do not let the O-ring fall inside the intake: it is reused for the supplied block off plate with the Polar Diesel logo in a later step. Rotate as necessary for removal.
Reinstall the intake silencer that was previously removed.
37 Remove the secondary EGR valve and crossover tube elbow
Remove the 2 bolts (highlighted red), then remove the secondary EGR valve and crossover tube elbow. Be careful not to drop the engine side bolt into the exhaust manifold.
38 Install the stainless steel plate on the exhaust manifold
Reuse the factory hardware and gasket.
39 Install the black turbo block off plate
Reuse the factory hardware and gasket.
40 Install the black intake manifold block off plate
Reuse the factory O-ring and bolts.
HAND TIGHTEN ONLY.
41 Reroute the coolant hoses
Connect the heater core hose you disconnected earlier to the upper crossover hose using the supplied 5/8" double barb and supplied hose clamps (A).
Connect one end of the supplied hose to the lower crossover coolant hose with the supplied barbed reducer and hose clamps (B). Remove the factory hose from the turbo coolant line and connect the other end of the supplied hose (C).
42 Reroute the EGR crossover coolant line
The coolant line that was bolted to the EGR crossover pipe can be re-routed under the intake using the supplied small double barb fitting. Disconnect and remove the coolant hose clamp (highlighted red).
43 Refill the coolant system
Follow the factory bleeding procedure.