XDP Duramax LBZ EGR Delete Item Number

XDP Duramax LBZ EGR Delete
Item Number: XD165
PACKING LIST:
1 – LBZ EGR Delete Plate for Up Pipe
1 – LBZ EGR Delete Plate for Intake
1 – Standoff A
1 – Standoff B
1 – Standoff C
6 – M8x1.25-20mm Bolt
1 – M10x1.25-20mm Bolt
1 – M10x1.5-80mm Stud
1 – M10x1.5-95mm Stud
2 – M10x1.5 Flange Hex Nut
1 – EGR Valve Seal
1 – EGR Valve Seal
1 – EGR Gasket
1 – 20" 5/8" Heater Hose
2 – 5/8" Hose Clamps
Before removing any parts from your truck, please compare the items you have received with the packing list
provided to verify that you have everything necessary to install your XDP Duramax LBZ EGR Delete.
WARNING: This high performance product is intended SOLELY for closed-course racing use and is not street
legal in ANY state. This product cannot be used on any vehicle that is registered or certified for highway use.
*Aftermarket Tuning Required*
Ensure that the vehicle has not been in use and that the engine is cool to the touch. Always wear eye
protection when working on any vehicle.
* PLEASE READ INSTRUCTIONS PRIOR TO INSTALLATION *
XDP Duramax LBZ EGR Delete (XD165)
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XDP Duramax LBZ EGR Delete
Step 1: Disconnect negative battery
cables.
Step 2: Remove passenger side
inner fender.
Step 3: Remove coolant tank cap.
Step 4: Locate the lower radiator
hose on the passenger side of the
radiator.
Step 5: Remove the butterfly clip.
Step 6: Place a drain pan under the
passenger side of the radiator.
Step 7: Gently pull the radiator hose
back to drain. (The coolant will drain
quickly.)
Intake Tube
Step 8: Remove the resonator and
intake tube.
Step 9: Remove the (3) wiring
harness retaining bolts on top of the
intake bridge using a T30 torx drive.
Step 10: Remove the (2) bolts
retaining the cast aluminum CAC
pipe.
Resonator
Bolt 1
Bolt 2
XDP Duramax LBZ EGR Delete (XD165)
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Step 11: Remove the bolt retaining
the dipstick tube.
Step 12: Remove the ignition wire
for the intake air heater.
Step 13: Disconnect the MAF sensor
connector.
Step 14: Remove the EGR actuator
connector on the passenger side of
the truck.
XDP Duramax LBZ EGR Delete (XD165)
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Step 15: Remove the butterfly clip
retaining the cast aluminum CAC
pipe and the plastic CAC pipe
together.
Step 16: Remove the wiring harness
bracket connected to the stud on
the intake horn by removing the nut
with a 12mm socket.
Step 17: Gently pull the wiring
harness towards the front of the
truck.
Step 18: Remove the bolt holding
down the PCV hose to the valve
cover on the passenger side of the
motor with a 10mm socket.
XDP Duramax LBZ EGR Delete (XD165)
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Step 19: Use needle nose pliers to
remove the spring clamp on the
turbo intake. Lay the PCV hoses over
to the driver side of the truck.
Step 20: Remove the turbo vane
actuator solenoid connector and set
aside.
Step 21: Loosen the band clamp on
the turbo intake mouthpiece and
remove
XDP Duramax LBZ EGR Delete (XD165)
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Step 22: Remove the (4) bolts
retaining the intake bridge. Set the
intake bridge aside.
Step 23: Remove the heater core
coolant hose that is closest to the
driver side of the truck.
Step 24: Remove the two nuts
retaining the EGR cooler to the uppipe.
Nuts are removed
from the back of this
flange
Step 25: Remove the two bolts
retaining the EGR cooler to the EGR
cooler bracket.
Bolts retain the cooler in
this bracket
XDP Duramax LBZ EGR Delete (XD165)
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Step 26: Using a 14mm socket
remove the two bolts on the front of
the EGR cooler and remove the
cooler.
Step 27: Clean the up-pipe sealing
surface to ensure a proper seal.
Step 28: Install the up-pipe blocker
plate and gasket. Use the two
M8x1.25-20mm bolts to retain the
blocker plate to the up-pipe. (Make
sure you tighten these two bolts
before moving tightening the M10
bolt.) Use the M10 bolt with the
correct thread pitch, found in the
previous step, to retain the up-pipe.
Photo shows an LMM
Step 29: Install the heater hose on
the two open coolant ports and
secure with supplied hose clamps.
XDP Duramax LBZ EGR Delete (XD165)
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Step 30: Set standoff A in the
mounting location of the EGR
actuator closest to the alternator.
Step 31: Set the wiring harness ring
terminal on top of standoff A.
Step 32: Install the 95mm stud
through the wiring harness ring
terminal and standoff A.
Step 33: Install standoff B on the
90mm stud.
Step 34: Install the 80mm stud in
the outer most bolt hole that
previously retained the EGR motor.
Step 35: Install standoff C on this
stud.
Standoff B
Standoff A
Wiring harness ring
terminal
Standoff C
Step 36: Install the intake bridge
bracket with the long straight edge
toward the front of the truck and
the laser engraving facing down.
Step 37: Retain the intake bridge
with the two M10 flange head nuts.
(Do not tighten the flange head nuts
yet.)
Step 38: Clean the sealing surface of
the intake bridge.
Step 39: Lay the intake bridge
gaskets in their appropriate location
on the intake bridge support plate.
Step 40: Install the intake bridge on
the intake horn and support plate.
Fasten the intake bridge to the
support plate using (4) M8x1.2520mm flange head bolts and use
factory fasteners to refasten the
intake bridge to the intake horn.
Step 41: Tighten the two M10 flange
head nuts on the studs.
XDP Duramax LBZ EGR Delete (XD165)
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Step 42: Reinstall the cast aluminum CAC pipe and retaining bolts.
Step 43: Reinstall the turbo intake mouthpiece. Do not tighten.
Step 44: Reinstall the PCV on the passenger side valve cover and into the intake mouthpiece.
Step 45: Reinstall the turbo vane actuator solenoid connector.
Step 46: Reinstall the intake pipe from the mouthpiece to the air filter box. Tighten both ends then tighten
the mouthpiece.
Step 47: Reinstall the resonator and PCV tube.
Step 48: Ensure the radiator drain plug is closed and refill the cooling system with coolant.
Step 49: Connect the battery cables.
Step 50: Start the truck and check for leaks.
Step 51: Drive the truck to further check for coolant leaks and check for drive pressure leaks. (A drive
pressure leak will create a squealing sound.)
PLEASE CONTACT XDP (1-888-343-7354) FOR TECHNICAL ASSISTANCE
XDP Duramax LBZ EGR Delete (XD165)
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