Diesel Tech EGR Bypass Kit - 6.0L EGR Solution Race-Only

Next, Taylor removed the variable-geometry turbo (VGT) solenoid for the turbo, the oil filler tube from the passenger-side valve cover, the heater hose tube, and all injector harness plugs.

It's important to be careful when removing the injector harness plugs. Each plug is spring-loaded and should not be yanked out. It was also important to make sure they plugged back in the same way later on. In addition, Taylor removed the fuel injection control module (FICM), which was not necessary, but provided more working space.

Another fragile aspect of the removal process was the cooling fan plug. While unplugging it is easy due to the male connection being held on by a plastic bracket, it's one of the most common components people break when performing EGR system repairs.

Next, the oil filter and fuel filter assembly had to be removed. The oil filter housing cap was loosened with a wrench, but was not removed immediately. The guys at Diesel Tech told us that, due to a check valve inside, and in order to avoid a mess, it's best to let the cap sit loose on top of the reservoir for a minute to allow the oil to drain back into the engine.

When it came time to remove the fuel return lines from the fuel filter housing, Taylor tightened zip ties around the lines to keep the fittings from slipping down. Then he removed the oil filter and fuel filter assembly.

After that, the turbo was pulled, exposing all intake bolts, which were removed, along with all EGR cooler bolts, all fan shroud bolts, and the throttle body.

Then the intake manifold was removed, followed by the EGR cooler (or as we like to refer to it at Diesel Power: the "toilet seat"). The difference between this '03 intake and an '04-and-newer one is where the turbo mounts. On '04-and-newer models, a different turbo pedestal led to the intake not connecting underneath the turbo. The U-shaped style intake can be used on '03 model engines, but the '03 model's oval-shaped intake cannot be used on '04-and-newer 6.0L's. Taylor chose to ditch this '03 manifold and re-install an intake manifold off an '05 engine (U-shape) for less clutter around the turbo.

This round 6.0L EGR cooler is off an '03 engine. The '04 models introduced a rectangular version that proved more problematic. Early '04 engines also came equipped with different EGR valves.

You can tell that engineers realized the limitations of the EGR cooler on 6.0L engines as opposed to the new 6.4L Power Stroke. The '08 6.4L's EGR system (shown) features two EGR coolers, one across the front of the engine, and the other laying flat along the driver-side exhaust manifold. And as if that wasn't enough, Ford even increased its radiator size for the new mill so much that it required re-working the '08 Super Duty's frame to make it fit!