Installation Instructions - H&S Performance

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 Ford 6.0L Powerstroke EGR/EGR Cooler Delete Kit Installation Manual

Included parts: 

1- Aluminum EGR Valve Plate with O-Ring 

1- Aluminum EGR Cooler Plate with O-Rings 

1- 180 Degree Stainless Steel Coolant Tube 

1- Stainless Steel Up Pipe 

1- Up pipe gasket 

1- 3/4” Silicone Hose 

2- 3/4” Hose Clamps 

2- 5/16 X 1.25” Bolts 

2- 5/16 X 2.5” Bolts 

4- 5/16 Nuts 

STEP 1 

Un-hook battery terminals, drain the engine coolant and remove clips from the plastic wire 

way just above the turbo, fold to windshield of truck. 

Plastic Wireway 

STEP 2 

Remove the radiator over flow reservoir by removing 3 hose clamps (the third hose clamp is 

on the bottom side of the reservoir), and 2 bolts. 

Clamps 

Bolts 

1-888-628-1730 • www.hsperformance.com 3

STEP 3 

Remove the intake tube assembly by loosening the hose clamp, un-clipping the MAP sensor 

harness and removing 2 bolts. 

Clamp 

Bolts 

STEP 4 

Remove upper fan shroud by prying away from radiator through slots. 

STEP 5 

Remove charge pipe by loosening two hose clamps (one on bottom and top of the tube). 

Charge Pipe 


STEP 6 

Remove Alternator. Disconnect both wire harnesses and remove 3 bolts. 

STEP 7 

Disconnect down pipe by removing v band clamp from back of turbo. 


STEP 8 

Remove turbo charger. This is done by removing the VGT actuator wire, two oil feed line 

bolts, up-pipe v band clamp, and the three turbo mounting bolts. It is strongly recommended 

to use penetrating oil on all turbo bolts, exhaust up pipe bolts, and pedestal bolts. 

Once these parts are removed the turbo will roll toward the passenger side of the truck and 

out of the pedestal. 

STEP 9 

Remove intake horn by loosening clamp, and removing 4 bolts. 


STEP 10 

Remove 4 Fuel lines and disconnect 3 wire harnesses. (two of the wire harnesses are located 

on the backside of the oil filter housing not shown in picture) 

STEP 11 

Remove the Oil and Fuel filter housing by removing 4 Hex bolts. 

STEP 12 

Remove two bolts from coolant line. 


STEP 13 

Remove two bolts that secure the fan shroud to the front of the intake manifold. Remove 1 

bolt from the fuel line bracket. 

STEP 14 

Remove 3 wire harnesses and remove 4 injector harnesses (use a flat head screwdriver to 

pry the metal harness clips away for removal). 

STEP 15 

Remove the boost line to MAP Sensor. 


STEP 16 

Remove the IPR harness (Injection Pressure Regulator) 

STEP 17 

Loosen 18 bolts using a 10 mm on the top of the intake manifold. Remove the manifold by 

lifting up and forward motion. 

STEP 18 

Loosen and remove the v band clamp from the up pipe to the EGR Cooler. 


STEP 19 

Remove EGR Cooler and coolant hose. 

STEP 20 

Remove 2 bolts on the bottom and 2 bolts on top of the up pipe. Remove up pipe. 

STEP 21 

Install the new up pipe using the supplied 5/16” nuts, bolts,and gasket. (The supplied 

gasket is to be used on the top side of the up pipe along with the 5/16 x 1.25” bolts) 


STEP 22 

Install the 180 degree stainless tube in the bottom of the intake manifold with the new 

bracket block off plate combo. 

STEP 23 

Reinstall intake manifold, replace and torque bolts to 120 in lbs. Remove the EGR Valve and 

replace with provided block off plate and O-ring. 

STEP 25 

Reinstall turbo, all intake and exhaust tubes including down pipe, alternator, shroud, wires 

etc. in reverse order. Refill with new coolant and start engine, check for any leaks and top off 

fluids as needed.

Installation Instructions - H&S Performance

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