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

With the intake manifold and EGR cooler removed, Taylor installed the new block-off plate.

Next, the intake air temperature (IAT) sensor was removed from the intake manifold and compared to a clean one. This should give you an idea of the kind of soot buildup that occurs in a factory EGR system. The IAT sensor on the left is new, the one on the right used. This sensor threads into the driver side front of the intake manifold.

This is the EGR plug that Diesel Tech offers with its competition-use-only bypass kits, which effectively eliminated the EGR system on race-only vehicles.

For minimal hassle, Taylor opted to flip the '05 6.0L intake over and installed the EGR cooler bypass tube before putting it on the truck.

With the new intake gaskets in place (PN 3C3Z-9433-AA), Taylor put the intake manifold on. He hand-tightened all intake bolts first, and then torqued them to 8 lb-ft. After that, Taylor reinstalled all the fan shroud bolts as well. It is important to note that no gaskets, O-rings, or seals should be reused in this type of install.

Here's a good look at the '05 intake and the EGR bypass tube. This was also an opportune time for Taylor to clean up the engine valley, valve covers, and areas on the cylinder heads that were exposed.

Taylor also upgraded the turbo oil drain tube from Ford (right) before reinstalling the turbo (PN 6C3Z-9T515-A).

With the turbo reinstalled, Taylor bolted on the oil filter and fuel filter assembly, plugged in the injector harnesses and the FICM, reinstalled the heater hose tube (torqued bolts to 10 lb-ft), and the alternator (torqued bolts to 35 lb-ft), bolted on the intake elbow (torqued clamps to 9 lb-ft), the overflow reservoir, and the air intake. After the install, Taylor told us the truck runs cooler and is more responsive in the mid- and top-end power range.