Sd-egrd-6.4-Ie (6.4l Egr Delete w Elbow) (1)

08-10 6.
4 POWERSTROKE
COMPLETE EGR DELETE
! WARNING REGARDING EMISSIONS LAWS
Not legal for sale or use on pollution-controlled motor vehicles anywhere in the
United States. Legal ONLY for off-road competition racing vehicles and cannot
be used on vehicles that are operated on public streets, roads, or highways.
! DISCLAIMER
1) By installing this product onto your vehicle, you assume all risk and
liability associated with its use.
2) It is your responsibility to make sure your vehicle complies with all

federal, state, and local emissions laws. Federal and many state and local
laws prohibit the removal, modification or rendering inoperative of any
part of the design affecting emissions or safety on motor vehicles used on
a public street or highway. Violation may result in a fine of up to $32,500
per vehicle (or possibly higher depending on changes in the law). All civil
penalties and fines for removing your vehicle’s emissions equipment are
the sole responsibility of the end user.
3) Due to its high performance nature, this product may void vehicle
manufacturer’s warranty.
4) Sinister Mfg Company, Inc. is not responsible for misuse of its products.
By installing this product, you release Sinister Mfg Company, Inc. of any
and all liability associated with its use.
5) Depending on where you live, restrictions may apply. Check all

applicable laws before installing or using!
6) The purchaser and end user releases, indemnifies, discharges and holds
harmless Sinister Mfg Company, Inc. from any and all claims, damages,
causes of action, injuries, or expenses resulting from or relating to the use
or installation of this product that is in violation of the terms and
conditions on this page, the product disclaimer, and/or the product
installation instructions. Sinister Mfg Company, Inc. will not be liable for
any direct, indirect, consequential, exemplary, punitive, statutory, or
incidental damages or fines caused by the use or installation of this
product.
1
6.4L EGR Delete With Intake Elbow
I E
C B
F D
G A
H
PACKING LIST:
Part# QTY. Description
A 1 Exhaust Block-Off Plate
B 1 Exhaust Gasket
C 2 Coolant Line Plugs
D 1 Brass Barbed Hose Connector
E 1 Stand-Off Spacer
F 4 M10-1.25 x 40 Hex Head Bolts (Exhaust Manifold)
G 2 M10-1.25 x 20 Hex Head Bolts
H 4 M6-1.25 x 25 Flanged Hex Head Bolts
I 2 Plastic Hose Routing Clips
J 1 Intake Elbow
Read all instructions prior to install.

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.
2
CAUTION!!! Never work on a hot vehicle. Serious
injury in the form of burns can result if the vehicle has
!
been in use. Allow the vehicle time 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 significant amount of time for the
chemical to lubricate the threads before attempting to disassemble.
Step 1: Make sure the front

wheels are straight.
Image 2.5 x 1.6376
Step 2: Disconnect both
batteries.
Step 3: Drain the coolant using Image 1

the coolant drain plug located on
the bottom of the radiator on the
driver side. (Image 1)
Step 4: Remove the 3/8” hose

that runs to the degas bottle
(coolant overflow tank). Keep this
hose as it will be re-used during
installation. (Image 2) Image 2
Step 5: Remove the upper

radiator hose by popping the wire
clip out and pulling the hose
straight out. (Image 3)
Image 3
3
Step 6: Remove the driver side
battery.
Step 7: Remove all of the

coolant hoses going to the
degas bottle. Also, remove the
vent line going to the battery
tray.
Image 4
Step 8: Remove the battery tray
and degas bottle. This is held on
by four bolts.
(Image 4 -shows parts removed)
Step 9: Loosen the clamp on

driver side intercooler tube and
separate the intercooler tube Image 5
from the rubber boot. It is not
necessary to remove the tube.
(Image 5)
Step 10: Disconnect the

electrical connector on top of
the vertical EGR cooler.
(Image 6)
Image 6
Step 11: Disconnect the

coolant lines on the vertical EGR
cooler. Remove the nuts and
bolts securing the coolers
together. Release the mounting
clamps and separate the two
coolers by prying on the
flanges. Image 7
(Image 7)
4
Step 12: Hold the intercooler
tube back while pulling the
vertical EGR cooler up and out.
You may have to rotate the
cooler to release it from its
mount. (Image 8)
Image 8
Step 13: Remove the plastic
coolant tube. Be careful to not
break the coolant tube as it will
be re-used during installation.
(Image 9)
Image 9

radiator hose from the
thermostat housing. If your
radiator hose has a single
O-ring it is a good idea to
replace it with a new double
O-ring version.
(Shown In Image 10) Image 10

EGR cooler mount. Use a 10mm
wrench to remove the three
bolts. Use a 13mm wrench to
remove the stud . Keep the stud
for securing the power steering
line during the install.
(Image 11) Image 11
5
Step 16: Remove the steering
shaft bolt and slide the stem up
and out of the steering box
shaft. Note: Be sure to not turn
the steering wheel or tires.
(Image 12)
Step 17: Remove the nut that

Image 12
secures the dipstick tube in
place. (Image 13)
Step 18: Release the mounting

clamps on the lower EGR
cooler. It may be easier to
access the clamps though the
wheel well.
(Image 13) Image 13
Step 19: Remove the coolant

line on the EGR Cooler. It may
be easier to cut the line. Note:
The line will not be re-used.
(Image 14)
Step 20: Remove the bolts on

the rear flange of the EGR
Image 14
cooler. It is easier to access the
bottom bolt from underneath
the truck and the top bolt from
above. (Image 14)
Step 21: With the dipstick

moved out of the way, remove
the EGR cooler by pulling
forward and rotating it out of
its mount.
6
Step 22: Remove the bolt
securing the coolant line to the
timing cover. This line is
attached to the lower EGR
cooler mount and will be
removed as one piece.
(Image15)
Image 15
Step 23: Use a 10mm wrench
to remove the four bolts on the
lower EGR cooler mount.
(Circled In Image 15)
Step 24: Install the four

replacement bolts
(M10-1.25 x 40) in the exhaust
manifold and torque to factory
Image 16
specifications. (Image 16)
Step 25: Install the exhaust

block off using M10-1.125 x 20
bolts and gasket. (Image 17)
Step 26: Remount the dipstick

tube with the factory bolt.
Image 17
Step 27: Remove the coolant
tube that was connected from
the vertical EGR cooler to the
engine. Replace it with the
coolant plug supplied in the kit
to block off the hole. (Image18)
Image 18
7
Step 28: Install the coolant
plug included in the Sinister
EGR delete kit. Use the factory
bolts that secured the lines in
place. (Image 19)
Step 29: Use 13mm wrench to

Re-install the stud using the
Image 19
spacer provided in the Sinister
EGR delete kit. Then secure the
power steering line to the stud.
(image 20)
Step 30: Re-install the plastic

coolant tube. Be careful not to
crack or break it.
(Image 21) Image 20
Step 31: Re-connect the

steering shaft and torque to the
factory specifications.
Step 32: Re-install the battery

box and degas bottle.
Step 33: Re-connect the Image 21

coolant lines to the degas
bottle. Also re-connect the vent
line to the battery box.
Step 34: Clean the end of the

silicone boot and intercooler
tube with glass cleaner.
Reconnect the intercooler tube.
8
Step 35: Re-connect the upper
radiator hose and make sure the
metal clips are securely in place.
Step 36: Disconnect the wire

connectors to the EGR valve.
(Image 22)
Image 22
Step 37: Remove four bolts and

loosen hose clamp on the
intercooler plumbing to remove the
EGR valve. (Image 23)
Image 23
Step 38: Install the intake elbow by

sliding the tube into the boot.
Using supplied M6-1.25 x 25 bolts
secure the flange to the intake
manifold. (Image 24)
Image 24
Step 39: Use the 3/8” hose that was
saved from step four and barbed
hose connection from the kit to
re-connect the coolant line running
over the radiator to the degas
bottle. The line will have to be cut
to appropriate length. Reuse
factory hose clamps on the
connections.
Image 25
(Image 25)
9
Step 40: Secure the coolant line
over the radiator with the plastic
hose routing clips. (Image 26)
Step 41: Refill the coolant

according to factory specifications.
Step 42: Run engine and check for

leaks.
10
2025 Opportunity Dr. Suite #7
Roseville CA, 95678
877-692-4110 - SinisterDiesel.com

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08-10 6.

2) It is your responsibility to make sure your vehicle complies with all

5) Depending on where you live, restrictions may apply. Check all

Read all instructions prior to install.

Step 1: Make sure the front

Step 3: Drain the coolant using Image 1

Step 4: Remove the 3/8” hose

Step 5: Remove the upper

Step 7: Remove all of the

Step 9: Loosen the clamp on

Step 10: Disconnect the

Step 11: Disconnect the

Step 14: Remove the upper

Step 15: Remove the upper

Step 17: Remove the nut that

Step 18: Release the mounting

Step 19: Remove the coolant

Step 20: Remove the bolts on

Step 21: With the dipstick

Step 24: Install the four

Step 25: Install the exhaust

Step 26: Remount the dipstick

Step 29: Use 13mm wrench to

Step 30: Re-install the plastic

Step 31: Re-connect the

Step 32: Re-install the battery

Step 33: Re-connect the Image 21

Step 34: Clean the end of the

Step 36: Disconnect the wire

Step 37: Remove four bolts and

Step 38: Install the intake elbow by

Step 41: Refill the coolant

Step 42: Run engine and check for

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