River City Diesel 6.4L Ford Egr Delete System.

Includes (2) 5/16x1.5 bolts. (2) 5/16 Flat washers. (2) 5/16 lock washers. (1) Coolant hose standoff. (1)Exhaust Block off plate. (1)EGR Cooler block off plate W/ O-ring seal. (2) Cooler hose plugs W/ O-ring seals. (1) Ford Exhaust Plate Gasket. (4) M8 Exhaust manifold bolts.

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Center Steering Wheel. Disconnect Battery Drain Coolant Remove 3/8 Hose From Cooler and Res. This can be discarded.

5 Remover upper radiator hose clip and pull hose loose from the radaiator.

6 Remove Drivers side battery, tray and coolant tank assembly. Be sure to remove vacuum hose from bottom of assembly. This must be reinstalled for vacuum system to work properly.

7 Remove band clamp nuts, hose clamps from hoses and unhook EGR cooler temp sensor.

8 Loosen and pull upper I/C tube hose out of silicone. It is unnecessary to remove entire tube.

9 Remove cooler to cooler nuts and pry apart off studs.

10 Remove cooler, twist and pull upward while holding I/C tube back.

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Remove plastic coolant Y to prevent breakage. This part is very brittle.

11 Remover upper vertical cooler cast iron bracket. (3) 10mm head bolts and (1) 13mm head stud. Save the stud. This will be reused to secure the power steering hose. 12 Note at the time if the hose is black where it attaches to the thermostat housing it should be replaced with the newer white hose that utilizes two O-rings to seal as oppsed to one. 13 Remove vertical cooler lower bracket. 14 Remove dipstick tube hold down nut.

15 Remove steering shaft bolt and slide loose.

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16. Loosen and remover nuts from lower horizontal cooler band clamp nuts. Some of these are easier accessible from the wheelwell.

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Remove or cut free horizontal rear cooler hose.

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18 Remove Horizontal cooler bolts from Exhaust Extension tube. (1) from top, one from underside of truck.

19 Rotate cooler to free dipstick tube and push dipstick tube to drivers side of steering shaft to get out of way temporarily.

20 Pull cooler upward and out toward the front.

21 (4) Ten mm head bolts hold horizontal cooler bracket to cyl head/exhaust manifold. These bolts are shared to hold the exhaust manifold in place. They will be replaced with new shorter bolts.

22 Remove cooler tube from timing cover and remove in one piece as pictured above. 23 Reinstall dipstick tube hold down nut. 24 Install 4 new exhaust manifold bolts and torque.

25 Remove upper cooler hose and steel line from front cover and discard.

26 Install New RCD coolant plugs where these lines came from.

27 Install Stand-Off under stud that was saved from earlier. Then reinstall power steering hose clamp to support it.

28 Reinstall Coolant Y into front cover. 29 Reinstall Steering shaft and torque to manuf. Specs. 30 Reinstall battery box assembly, not forgetting to reinstall Vacuum hose to bottom of tray. 31 Clean and reconnect upper silicone to I/C tube. It is imperitive to remove all oil residue with brake clean or an equivalent. This will prevent it from sliding apart under high boost pressure. 32 Reinstall Upper radiator hose and clip. 33 Attach coolant hoses to tank. 34 Refill coolant, run and refill after coming up to temp. 35 Enjoy your new RCD EGR delete!