Sinister Diesel 2004.5-2005 LLY EGR Delete Kit User manual

2004.5-2005 GM
6.6L DURAMAX LLY
EGR DELETE

2004.5-2005 LLY EGR Delete Kit
PACKING LIST:
QT Y.
2
1
4
2
4
2
1
1
1
Description
Billet EGR Block O Plates with O-Ring
M10 x 20mm Hex Head Bolt
M8 x 20mm Allen bolts (short)
M8 Flanged Nuts
M8 x 30mm Allen Bolts (Long)
Hose Clamps
Nickel Plated Steel Exhaust Block O
Stainless Steel Support Bracket
5/8”x17” Silicone Hose
Note: Prior to installation, please compare the parts that you have
received with the bill of materials provided on this page to assure
that you have all the parts necessary for the installation.
Part#
A
B
C
D
E
F
G
H
I
E
C
F
I
H
D
G
AB
Read all instructions prior to install.

!
CAUTION!!! Never work on a hot vehicle. Serious
injury in the form of burns can result if the vehicle has
been in use. Allow vehicle to cool prior to installation.
Always wear eye protection when working on or
under any vehicle.
Note:
With a used vehicle, we suggest using a penetrating spray lubricant to be applied
liberally to all exhaust fasteners. When doing so allow a signicant amount of time for the
chemical to lubricate the threads before attempting to disassemble. On your application
these are the bolts in step 8, located on the rear passenger side of the engine.
Step 1: Disconnect Batteries
Step 2: Drain coolant
Step 3: Remove intake resonator by
loosening hose clamp and support
bolt. (Image 1)
Step 4: Disconnect the mass air ow
sensor. Remove the intake tube by
loosening the hose clamps on the
intake tube. (Image 2)
Step 5: Remove zip ties and pull
wiring away from intake charge tube.
(Image 3)
Image 2.5 x 1.6376
Image 1
Image 2
Image 3

Step 6: Remove the intake tube from
the vehicle. The intake tube is held in
place by one hose clamp and six bolts.
Two bolts secure the ange at one
end and the four remaining bolts
secure the intake tube to the EGR
Valve. (Image 4)
Note: Stu a clean rag in the rubber
boot to keep debris out of the intake
system.
Step 7: Remove the PCV hose on
passenger side of truck. (Image 5)
Step 8: Remove the four bolts and
nuts near the rewall that secure
the EGR cooler in place.
Step 9: Remove the 4 bolts and
nuts that hold the EGR valve to the
motor. Disconnect all coolant lines
running to the EGR cooler. The
entire EGR assembly can now be
pulled up and out. Be sure to save
the exhaust gasket for installation
of the block o plate. (Image 6)
Step 10: Pre-assemble the charge
tube with the supplied blue block
o plates with O-rings. Note: Be sure
to install the two longer bolts on the
front side of the tube. (Image 7)
Image 4
Image 5
Image 6
Front
Image 7

Step 11: Install the supplied
support bracket to the motor,
re-using one of the factory bolts
and the supplied M10 x 20 hex
head bolt. (Image 8)
Step 12: Reusing the Factory
gasket, install the exhaust block-o
with the supplied 20mm and 30mm
bolts. All bolts will be installed from
the backside of the block-o
plate.(Image 9))
Step 13: Replace EGR coolant lines
with the supplied Sinister coolant
line. This will reconnect the coolant
from the rewall to the thermostat.
(Image 10)
Step 14: Re-install intake tube with
the front long bolts going through
the previously installed support
bracket. (Image 11)
Step 15: Reverse earlier steps to
re-install the pcv hose, electrical
wires, intake and intake resonator.
Step 16: Rell Coolant to factory
specications. Run Engine and
check for leaks. Top o the coolant
as needed.
Image 8
Image 9
Image 10
Image 11

2004.5-2005 LLY Duramax
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2004.5-2005 LLY Duramax
Upgraded EGR Cooler
Race Fuel Valve