INTRODUCTION
Warning!
This high performance product is intended for o-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 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
KIT CONTENTS
REmOvEd paRTS
• One Exhaust Manifold Block-o Plate
• One Intake Block-o Plate
• One Coolant Block-o Plate
• One 1” Hose Clamp
• One Straight Barbed Fitting
• One Vacuum Cap
• One Pressure Sensor Bracket
• One Pressure Sensor Bracket Hardware
• Two 3/4” Coolant Caps
• Three 8mm Bolts
• Three 8mm Washers
• Three Zip-Ties
Pictured above are the major components that will be removed from the vehicle during this
installation guide.
STEp 1
Drain coolant from both coolant systems. Remove caps from both radiator overow tanks. The drain
for the cold coolant system is found on the passenger side and the drain for the hot coolant system
is found on the driver side. Drain about 3 gallons from the hot system and about 2 gallons from the
cold system. You may need to use multiple buckets. After draining, close both drain plugs.
STEp 2
Disconnect the negative terminals from both batteries using an 8mm wrench.
4 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 3
Unplug the MAF sensor located on the air intake. The red locking tab will need to be pulled out
before harness can be unplugged. Unclip the MAF sensor wire harness from the air box.
STEp 4
Remove the two 8mm bolts holding the intake box and air reserve chamber.
STEp 5
Loosen the two clamps located on intake system.
STEp 6
Pull up rmly on air box to dislodge it from lower rubber mounts. Slide coupling o of the air box
and remove it from the vehicle.
6 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 7
Dislodge the three coolant lines attached to the remaining portion of the air intake and remove the
remaining portion of the air intake from the vehicle.
STEp 8
Disconnect clips and brackets holding the two larger coolant lines. Using pliers from the top of the
vehicle, loosen the three factory clamps on larger coolant lines and pull lines o of connections.
Using a long athead screwdriver from the bottom of the vehicle, pry remaining coolant line end
away from radiator as much as possible while someone else pulls rmly on coolant line from above
to disconnect from radiator. Remove both coolant lines from vehicle.
8 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 9
Remove the two permanent clamps on the small coolant line tee shown below. Install supplied
straight barbed tting, eliminating the line that goes to the EGR system.
STEp 10
Using the factory clamp, install a supplied 3/4” cap onto cold coolant system reservoir. From the top
of the truck, slide the other supplied 3/4” cap and supplied hose clamp onto the cold coolant system
radiator. Using a long athead screwdriver, tighten clamp from underneath vehicle.
10 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 11
Disconnect the snap-tted coolant line from the metal coolant pipe. Press tabs on both sides of tting and slide o. Tuck line away from EGR system.
STEp 12
Unplug harness from temperature sensor in EGR piping. Zip-Tie remaining harness out of the way of
moving/hot parts.
STEp 13
Unplug harnesses from the Powertrain Control Module (PCM) located on the passenger side rewall.
Tuck harnesses away from EGR system.
STEp 14
Unplug the three harnesses located on top of the EGR cooler. The orange harness has a yellow lock
tab that must be slid out before the harness can be unplugged. The black harness has a metal locking clip that must be pried out before the harness can be unplugged. Re-install the metal locking
clip after unplugging to prevent losing the small clip.
12 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 15
Unplug vacuum line from EGR system. Remove 90 degree end from vacuum line and install supplied
vacuum cap.
STEp 16
Unplug the EGR Buttery Valve located near the radiator fan shroud.
STEp 17
Remove two bolts holding wiring harness to front of EGR cooler.
STEp 18
Remove two clips holding black re retardant heat shield to passenger side of EGR cooler.
14 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 19
Remove the four 8mm bolts from the short EGR pipe and remove the short EGR pipe from vehicle.
Retain bolts and gaskets for later use.
STEp 20
Remove the two 8mm bolts from the bracket holding the long EGR pipe to the EGR cooler. Remove
the four remaining 8mm bolts from the long EGR pipe and remove the long EGR pipe from vehicle.
Retain bolts and gaskets for later use.
STEp 21
Remove the seven 8mm bolts holding the EGR system to the passenger side intake manifold.
Remove the 10mm nut holding the pressure line bracket to the back side of the EGR cooler.
STEp 22
Pull the EGR system towards the front of the truck. You may need to twist the EGR system slightly
counter-clockwise in order to clear the black intake “Y”. Once EGR system is pulled slightly forward,
there is a clip holding a wiring harness to the back side of the EGR cooler that will need to be
removed (shown below with EGR system removed). Ensure no other harnesses or clips are still connected to EGR system and remove the EGR system from vehicle.
16 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 23
Reconnect PCM harnesses to PCM, ensure you have a good connection. Zip tie unused EGR harnesses
and vacuum line to PCM harness.
STEp 24
Reconnect the coolant line with the snap tting, ensure the line “clicks” in.
STEp 25
Using previously removed hardware and gasket, install the supplied exhaust manifold block-o
plate (smallest plate). Tighten.
STEp 26
Using previously removed hardware and gasket, install the supplied intake block-o plate (medium
sized plate). Tighten.
18 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
STEp 27
Slide the three supplied 8mm washers onto the three supplied 8mm bolts. Using the hardware,
install the coolant block-o plate (largest plate). Tighten.
STEp 28
Remove the rear-left (passenger side closest to the rewall) bolt on the black intake “Y”. Using factory bolt, loosely install supplied Pressure Sensor Bracket. Using supplied small bolt, washers, and
nut, bolt previously installed bracket to the pressure line hook-bracket. Tighten all hardware.
STEp 29
Reinstall intake system. Reconnect MAF sensor. If the small coolant line is long enough, route line
through old routing tabs on intake system.
STEp 30
Reconnect batteries. Rell coolant systems. Start the vehicle and ensure there are no leaks present.
Burp coolant systems and add coolant as necessary.
20 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
WaRRaNTY & dISCLaImER
All EGR Kits are considered high performance racing parts, and are intended and developed for
non-street-legal, o-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 certied 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 certied 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
liabilities, including but not limited to, loss of vehicle warranty, nes, 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 consequential damages.
NOTES
22 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
HARD PARTS
H&S oers many performance parts for late model
diesel trucks. Please visit our online store to see what
we have to t your truck.
EXHAUST PRODUCTS
H&S Performance carries a full line of mandrel bent
exhaust. Whether you desire 4” or 5” we have a kit to
suit your needs. We also carry a full selection of stainless tips to nish it o with some style.
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24 Ford 6.7L Powerstroke EGR/Cooler Delete Installation Manual
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