EGR/EGR Cooler Delete Kit Installation Guide 11 - Flo-Pro

EGR/EGR Cooler Delete Kit Installation Guide 11 - Flo-Pro
1-888-628-1730
1-888-628-1730
• EGR/EGR •Cooler
BlackDelete
Maxx Installation
Kit Installation
Manual
Guide 1
INTRODUCTION
Warning!
This high performance product is intended for off-road, closed-course racing use ONLY. This
product may never be installed on a vehicle registered for highway use. By installing the
EGR or EGR Cooler Delete Kit onto your vehicle, you assume all risk and liability associated
with its use. It is your responsibility to ensure that your vehicle complies with all national,
state, and local emissions laws. Due to its high performance nature, the EGR or EGR Cooler
Delete Kit may void vehicle manufacturer’s warranty. H&S Performance, LLC assumes
no liability for misuse of its products. By installing the EGR or EGR Cooler Delete Kit, you
release H&S Performance, LLC of any and all liability associated with its use. Any and all
civil penalties for removing your vehicles emissions equipment are the sole responsibility
of the end user. Check your laws before installing!
H&S Performance EGR delete kits are designed to be used in conjunction with an H&S Tuner.
If you are installing this EGR delete kit without an H&S tuner, you will almost certainly
get a Check Engine Light(CEL), as well as possible undesirable performance. If using
ANY other brand tuner besides H&S, please contact your particular tuner manufacturer to
determine if their tuning is designed to work in conjunction with an EGR delete kit.
TROUBLESHOOTING:
Please read and understand all installation instructions before proceeding with the
installation.
If you have questions during the installation of this product, please call H&S Performance
support at 1-888-628-1730
2 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
KIT CONTENTS
9
1
9
2
5
3
10
4
6
7
11
8
12
13
1 Three 5/16” X 1” Bolts & One 1/4” X 7/8” Bolt w/nuts & washers
8
One Crossover Tube Plug
2
One Threaded Stud
9
Two EGR Gaskets
3
One Bracket Spacer & Bolt w/washer
10
One EGR Plate
4
One Bracket
11
One Brass Plug (07-08)
5
One Coolant Line Plug w/O-Ring (09-10)
12
One Hose Clamp
6
One Small Cooler Plate
13
One Threaded Coolant Plug
7
One Large Cooler Plate
what your kit includes:
301001 - 07-08 EGR/Cooler Delete PICKUP & CAB/CHASSIS
KIT CONTAINS: #6, #7, #9, #10, #11, #12, #13 (Steps 1 - 19)
301002 - 2007-2010 EGR Delete
KIT CONTAINS: #8, #9, #10 (Steps 1 - 8)
301003 - 2007-2008 Cooler Delete PICKUP & CAB/CHASSIS
KIT CONTAINS: #6, #7, #11, #12, #13 (Steps 9 - 19)
301004 - 2009-2010 EGR/Cooler Delete PICKUP & CAB/CHASSIS
KIT CONTAINS: #1, #2, #3, #4, #5, #6, #7,#9, #10, #13 (Steps 1 - 30)
301005 - 2009-2010 Cooler Delete ONLY, PICKUP & CAB/CHASSIS
KIT CONTAINS: #1, #2, #3, #4, #5, #6, #7 (Steps 9 - 30)
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 3
STEP 1
Remove 4 - 8mm bolts, remove
dipstick, remove plastic cover
STEP 2
Remove 3 - 10mm bolts in dipstick bracket
4 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 3
Remove 4 - 10mm bolts in EGR housing, unplug EGR main harness
STEP 4
2010 - 2011
2007-2009
Unplug EGR airflow valve (AKA butterfly valve).
(shown here with intake manifold removed from vehicle for better picture)
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 5
STEP 5
Loosen clamps on both sides of EGR crossover pipe, remove 1 - 8mm
bolt in center of pipe (underneath)
STEP 6
Remove crossover pipe and re-install 8mm bolt
6 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 7
Replace gaskets (included) and install billet block-off plate
with factory 10mm bolts
STEP 8
If installing cooler delete, skip to step 9. If only installing EGR
delete, perform step 8, then STOP.
Install 2” billet block-off plug with factory clamp
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 7
STEP 9
Remove 3 - 10mm nuts and 2 - 8mm bolts, remove heat shield
STEP 10
Remove 4 - 10mm bolts and remove housing
8 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 11
Remove 4 - 10mm bolts. If pick-up model install front block off plate with factory
15mm bolts. If cab & chassis model skip to next step.
STEP 12
Remove 3 - 8mm bolts from top of servo, remove
4 - 10mm bolts and remove valve housing and
servo motor plate
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 9
STEP 13
Remove 2 - 15mm nuts and loosen clamp
STEP 14
Remove CCV hose and coolant lines
(it is normal for it to leak some coolant)
For 2010 vehicles, you may need to remove the lower bolt holding the forward
coolant pipe to get enough movement to remove the pipe from the cooler. Be
careful not to pull pipe off of the lower line or you will leak excess coolant.
10 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 15
Remove 2 - 15mm nuts and remove EGR cooler
STEP 16
Remove 2 - 14mm bolts and cooler mount
(bolts are hidden from
view on truck)
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 11
STEP 17
Install rear block-off plate
STEP 18
Remove 1 - 1/8” coolant fitting
12 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 19
Install threaded plug. For 2007 - 2008 models install brass plug in coolant line
and you are finished. For 2009-2010 models continue on to step 20.
STEP 20
Install coolant plug into coolant pipe. It is recommended that you apply a thin coat
of lubricant on the o-ring before installation. Ensure plug is pressed all the way in.
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 13
STEP 21
Remove header bolt (third from the rear).
STEP 22
Remove spacer from previously removed header
bolt and install spacer on supplied header stud.
14 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 23
Install header stud. Torque to 40-50 ft. lbs.
STEP 24
Thread supplied spacer onto previously installed header
stud. Tighten as tight as possible using fingers.
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 15
STEP 25
Using supplied M10 bolt and washer, bolt H&S bracket
to spacer. Finger tight only, do not tighten at this time.
STEP 26
Bolt H&S bracket to pressure line bracket using supplied 5/16” bolt, washers,
and nut. Tighten nut/bolt until snug, not tight.
16 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
STEP 27
Bolt H&S bracket to coolant pipe bracket using supplied 5/16” bolt, washers, and
nut. Tighten nut/bolt until snug, not tight.
STEP 28
Bolt transmission dipstick (Automatic Only) to H&S bracket using supplied 1/4”
bolt, washers, and nut. Do not tighten at this time.
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 17
STEP 29
Adjust H&S bracket and coolant pipe so that the plug and bracket are pressing
against each other firmly. Tighten all bolts.
STEP 30
Bolt crankcase breather pipe bracket to H&S bracket
using supplied 5/16” bolt, washers, and nut and tighten.
18 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
WARRANTY & DISCLAIMER
All EGR Kits are considered high performance racing parts, and are intended and developed for
non-street-legal, off-highway, closed course racing use ONLY!
Installation of this product on a non-sanctioned race vehicle, on ANY road, public or private, is
STRICTLY PROHIBITED in the United States and Canada. This product may cause the vehicle it is
installed on to exceed federal emissions limits, and therefore cannot be installed on any vehicle
that has been certified or registered for highway use. Removing your emissions equipment, including but not limited to, exhaust gas recirculation(EGR), catalytic converter, or Diesel Particulate
Filter(DPF), is against federal regulations set forth by the EPA, when not used for closed-course
sanctioned racing. H & S Performance, LLC strongly recommends that all emissions equipment
be left in place at all times on any vehicle that has been registered or certified for highway use.
By purchasing or installing this high performance product, you release H & S Performance, LLC of
any and all liabilities, and assume all responsibility for making sure your vehicle is compliant with
all local, state, and federal emissions regulations. By installing this product you agree to these
terms and conditions, and also acknowledge that installing a high performance product on your
vehicle may void your manufactures warranty. By installing this product, you assume all risks and
liabilites, including but not limited to, loss of vehicle warranty, fines, and/or civil penalties. By
installing this product, you assume all associated risks and liabilities, and in no way will hold
H & S Performance, LLC liable for any unlawful use, mis-use, or consequencial damages.
1-888-628-1730 • EGR/EGR Cooler Delete Kit Installation Guide 19
20 EGR/EGR Cooler Delete Kit Installation Guide • www.hsperformance.com
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