// Install guides
EGR DELETE — 07.5-10 DURAMAX 6.6L LMM
Never work on a hot vehicle. Let it cool before starting, and wear eye protection when working on or under it. The truck needs an emissions-removed tune before it is driven with the EGR removed. By installing this product you assume all risk and liability for its use.
Removing the EGR cooler and valve from a 2007.5–2010 Chevy/GMC 2500/3500 6.6L LMM Duramax and fitting the block-off plates, coolant re-route and support bracket. The cast intake comes off in sections to reach the cooler, and goes back on with the new plates in place. Kit contents: exhaust block-off plate, two intake block-off plates with O-rings, U-shaped coolant tube with hose clamps, support bracket with washer, and hardware (M8 x 25 and M10 x 20 hex bolts, cap head bolts, flange nuts). On a used truck, soak every exhaust fastener with penetrating lubricant and give it time to work before you start undoing anything.
Steps
1 Disconnect the batteries
2 Drain the engine coolant
Remove the passenger side inner wheel well and disconnect the lower radiator line by removing its metal clip. The line does not need to come all the way off, only far enough for coolant to flow out. Once the flow has slowed and the overflow bottle is empty, reconnect the lower radiator line.
3 Loosen the intake hose clamps and disconnect the MAF sensor
4 Remove the intake tube
It runs from the filter to the plastic turbo mouthpiece.
5 Remove the air box and filter
Gently pry out the three rubber grommets that hold the box.
6 Remove the resonator box on top of the engine
Loosen the hose clamp at the base of the resonator box and remove the long bolt on its front.
7 Disconnect the charge-back wire on the alternator
Also remove the plastic clip that holds the wiring harness to the plastic wireway.
8 Disconnect the heater grid power wire
Open the plastic housing on top of the intake heater grid and disconnect the power wire inside.
9 Free the plastic wireway
Remove the two bolts and one nut that secure it in place.
10 Disconnect the connector on the front of the heater grid
Then remove the bolt that secures the connector wires to the side of the intake.
11 Remove the plastic clip holding the rest of the wire
12 Disconnect the plastic intercooler pipe from the cast intake
Pop out the metal retaining clip on the plastic intercooler piping and pull the plastic piece off the cast aluminium piece.
13 Unbolt the forward section of the cast intercooler piping
Remove the wire connector and the four bolts that hold the forward-most section to the intermediate section. On the underside of the forward piece there is a fifth bolt to a support bracket, circled in the photo of the previous step.
14 Remove the forward piece of the cast intercooler piping
Take care not to damage the gasket. It is reused on reassembly.
15 Remove the small tube on the cast intake
It sits next to the intake heater grid.
16 Remove the main section of the cast intake
Four nuts and two bolts hold it. Two of the bolts are on the back side of the main section. It comes out of the truck more easily if you remove the two studs with a reversed torx socket.
17 Remove the PCV tube
Disconnect it from the driver and passenger side valve covers and from the plastic turbo mouthpiece.
18 Remove the plastic turbo mouthpiece
Loosen the hose clamp that secures it to the turbo.
19 Remove the two temperature sensors from the EGR cooler
They are on the passenger side of the cooler.
20 Disconnect every coolant line running to the EGR cooler
21 Remove the EGR cooler
Six bolts hold it: four at the back of the cooler, two facing forward and two facing down, and two rear-facing bolts at the front.
22 Remove the temperature sensors from the truck
With the cooler out, disconnect the sensors at their electrical connectors and take them out.
23 Remove the EGR valve
Two bolts hold it. Keep one of them; it is used when the support bracket goes on.
24 Remove the coolant lines that ran from the EGR cooler to the firewall
25 Install the exhaust block-off plate
Use the factory gasket and the supplied hardware. Two M8 x 25 hex head bolts go in from the back, and one M10 x 20 hex head bolt holds the bracket in place. The photo shows an earlier bracket design; the fitting is the same.
26 Install the U-shaped coolant tube
It runs from one firewall port back to the other, the two ports that previously fed the EGR cooler. Secure it with the supplied hose clamps.
27 Install the support bracket where the EGR valve was
The bracket washer goes underneath the bracket on the M10 x 20 hex head bolt. The other bracket bolt is the one you kept from the EGR valve.
28 Install the intake block-off plates
Fit both billet plates with their O-rings onto the cast intake using the remaining supplied cap head bolts. The longer bolts go on the side towards the front of the vehicle.
29 Refit the plastic mouthpiece and the PCV tube
30 Refit the main section of the cast intake
The two longer bolts, now towards the front, line up with and pass through the two remaining holes in the support bracket. Secure the intake to the bracket with the supplied flange nuts.
31 Refit the forward piece of the cast intake
Take care not to damage the gasket. Once it is on, reconnect the wire connector to the throttle plate.
32 Refit the plastic intercooler piping
33 Reconnect the heater grid wire
Then mount the wire support bracket back in place.
34 Mount the wiring harness back on top of the cast intake
It sits in the plastic liner. Put the small metal bracket back onto the stud.
35 Reconnect the small sensor tube
It goes to the port on the cast intake next to the heater grid.
36 Reconnect the heater grid power wire
It runs to the top of the heater grid under the plastic housing.
37 Reconnect the charge-back wire on the alternator
Use the plastic clip to hold the wiring harness to the plastic wireway again.
38 Refit the intake resonator box
It sits on top of the plastic turbo mouthpiece. Secure it with the hose clamp and the long bolt at its front.
39 Refit the air box, filter and intake tube
Reconnect the MAF sensor and tighten the intake hose clamps.
40 Reconnect the batteries and refill the coolant
Fill to factory specification.
41 Start the engine and check for leaks
Let it idle for a few minutes and top up the coolant as the system burps air.