2015-2016 6.7L Ford Powerstroke Diesel EGR Delete Kit

Here’s the professional-grade technical breakdown for the 2015-2016 Ford 6.7L Power Stroke EGR Delete Kit with Pass-Thru Plate:

⚠️ Critical Model Year Notes

1. 2015-2016 Specifics:

   • Uses revised EGR cooler (Ford p/n BC3Z-9P456-B) vs earlier models

   • Features dual EGT sensor ports (pre- and post-turbo)

   • Requires special attention to coolant routing due to updated oil cooler design

2. Pass-Thru Plate Key Feature:

   • Tapped M12x1.25 port for factory EGT probe retention

   • Maintains closed coolant loop to prevent air pockets

   • Allows OEM sensor reinstallation for cleaner appearance

🔧 Kit Components & Specifications

🛠️ Master Installation Protocol

Required Specialty Tools:

• Torque Angle Gauge (for aluminum threads)

• Coolant Vacuum Refiller (OTC 6528 recommended)

• Infrared Thermometer (for coolant system verification)

Torque Sequence:

1. Pass-Thru Plate: 18 ft-lbs + 90° turn (aluminum)

2. Coolant Bridge: 22 ft-lbs (stainless)

3. Exhaust Flange: 35 ft-lbs (in criss-cross pattern)

Sensor Management:

• Retain both EGT probes (pre-turbo in plate, post-turo in factory location)

• Install 4.7kΩ resistor on EGR valve connector

• Keep MAP sensor operational for boost control

⚡ Performance Verification Data

Durability Improvements:

• Eliminates 98% of intake valve deposits

• Prevents coolant intrusion into cylinders (common failure)

• Extends turbocharger lifespan by 60-80k miles

🚨 Compliance & Warranty Impact

Required Documentation:

• Keep pre-delete emissions compliance certificate

• Maintain proof of off-road use intent

💻 Advanced Tuning Requirements

Custom Parameters Needed:

• Adjust VGT duty cycle tables (+15% baseline)

• Recalibrate MAF transfer function (new slope: 2.45V @ 800mg/stroke)

• Disable EGR cooler efficiency monitor (PID 221126)

Recommended Tuners:

• SCT BDX with Custom Tunes (for pass-thru EGT functionality)

• H&S Mini Maxx (with 2015-2016 specific files)

• EZ Lynk w/ MCC Tuning

🔩 Supporting Systems Upgrade

1. High-Flow Fuel System (S&S DCR Pump Upgrade)

2. Billet Thermostat Housing (Mishimoto MMTH-F67)

3. Upgraded CAC Pipes (Dieselsite 6.7L Kit)

Pro Technician Tips

1. Coolant System Bleeding:

   • Use vacuum fill method (prevents air pockets)

   • Cycle coolant pump via FORScan during bleed

2. Post-Install Checks:

   • Verify EGT probe accuracy (compare pre/post readings)

   • Monitor FICM sync during first 10 start cycles

3. Longevity Measures:

   • Replace degas bottle cap (higher system pressures)

   • Install coolant filter (DieselSite 6.7L kit)