Thank you for purchasing a Sinister Manufacturing Company EGR delete kit. Precision manufactured using aircraft quality billet aluminum; this EGR kit is designed to endure years of heavy use. Installing a Sinister EGR kit on your vehicle will eliminate the restrictive design allowing your turbo to get more air while preventing coolant from leaking into the intake. The result is a slight gain in horsepower and longer engine life. These installation instructions have been written to help you in the installation of your Sinister EGR kit. Please read it completely before installing your kit.

This Kit has been designed for:2010-2011 Dodge 2500/3500 crew cab, long bed, short bed equipped with a 6.7L Cummins turbo diesel engine and automatic or manual transmissions

This kit may void factory warranty please check with manufacturer.

This kit is intended for off-road use only.

Sinister Manufacturing Company recommends that a diesel shop or professional after market parts installer,who has all the necessary equipment, tools and experienced personnel needed for proper installation,should perform the installation of this system. However, if you decide to perform the installation, werecommend someone should help you. Ensure the installer uses all under car safety precautions includingeye protection.

Please take time to read and understand the following…By installing your Sinister EGR kit , you indicate that you have read this document and you agree with the terms stated below. It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Sinister EGR kit.

Sinister Manufacturing Company assumes no responsibility for damages occurring from misuse, abuse,improper installation, improper operation, lack of responsible care, or all previously stated reasons resultingfrom incompatibility with other manufacturer’s products and/or systems.

Included with your Sinister EGR kit is a warranty card. Please read it carefully before you begin any work on your vehicle. If you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Sinister EGR kit, please give us a call at the number provided on the warranty card.

Please call us at 877-692-4110 Mon-Fri 8am-5pm if you need any additional assistance.

Copyright c 2008 Sinister Mfg. Company 2025 Opportunity Drive Ste 7, Roseville, CA 95678

Sinister Mfg. Company Diesel EGR bill of materialsSinister Mfg. Company Diesel EGR bill of materials

Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If thevehicle has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always weareye protection when working under any vehicle.

Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of yournew Sinister EGR Delete Kit (for exhaust removal).

Note: Before removing the original parts from your vehicle, please compare the parts you havereceived with the bill of materials provided on this page to assure that you have all the partsnecessary for the installation of your new Sinister EGR kit.

Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally to all exhaustfasteners and allowing a significant period of time for the chemical to lubricate the threads beforeattempting to disassemble.

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PACKING LIST:

QTY. DESCRIPTION1 Support Bracket1 Coolant hose2 Hose Clamps4 M8 x 1.25 x 20 Bolts3 Block-Off Plates1 Stand-off Bolt1 Coolant Hose Connector1 M10 Flange nut2 M10 Bolts1 ¼-20 Bolt, Nut, and Lock Washer2 5/16 Bolts, Nuts, and Flat Washers

Original EGR System RemovalOriginal EGR System Removal

Figure 1.0Figure 1.0

Step 1: Disconnect BatteriesStep 2: Drain coolantStep 3: Remove 4 screws from plastic cover and remove cover figure 1.0

Step 4: Loosen V-band clamps and remove crossover pipe figure then unplug and disconnect Intake valve 2.0/2.1

Figure 2.0Figure 2.0 Figure 2.1Figure 2.1

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Step 6: Unplug throttle valve located under intake elbow 4.0, top view of throttle valve 4.1

Step 5: Remove 4 screws and electrical plug from intake valve figure 3.0. Remove any existing gasketmaterial from intake manifold figure 3.1

Step 7: Install Sinister intake plate with supplied bolts making sure o-rings are fully seated figure 5.0. Then remove heat sheild from EGR bypass figure 5.1.

Figure 4.0Figure 4.0 Figure 4.1Figure 4.1

Figure 3.0Figure 3.0 Figure 3.1Figure 3.1

Figure 5.0Figure 5.0 Figure 5.1Figure 5.1

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Step 8: Remove 4 bolts to exhaust bypass Figure 6.0

Step 9: Remove exhaust servo motor and exhaust bypass together figure 6.1

Step 10: Remove 4 EGR Cooler mounting bolts and disconnect all hoses. Figure 7.0

Figure 6.0Figure 6.0

Figure 7.0Figure 7.0

Figure 6.1Figure 6.1

Figure 7.1Figure 7.1

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Step 11: Remove v-band clamp from front of EGR Cooler figure 8.0, followed by the two bolts that hold thecrossover elbow in place. figure 8.1

Step 12:Bolt on the exhaust manifold block off plate before removing the cooler to prevent getting debrisinto the exhaust manifold. Figure 9.1 (Use the plate that does not have the NPT plug in it.)

Figure 8.0Figure 8.0

Figure 9.0Figure 9.0

Figure 8.1Figure 8.1

Figure 9.1Figure 9.1

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Step 13: Remove the bolts that are holding the tabs from the surrounding lines to the EGR cooler tray. Thereare three total, one is not pictured here. The third is the tab that is connected to the coolant hard line.Figure 10.0

Figure 10.0Figure 10.0

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Step 14: Remove the two nuts that hold the EGR cooler in place. They are located under the rear ofthe cooler and are difficult to see. Once they are removed, lift the cooler flange off of the studs andpull the cooler back towards the firewall until the front coolant line on the cooler is out of the hard line.

Step 15: Once the cooler has been removed, bolt on the second exhaust manifold block off plate.Figure 11.0

Figure 11.0Figure 11.0

Step 16: Remove the two bolts that hold the EGR cooler tray in place. The bolt heads are located underneaththe tray and are difficult to see. Figure 12.0

Figure 12.0Figure 12.0

Step 17: Remove the third from the rear exhaust manifold bolt and replace it with the Sinister hex stud spacer.

Figure 13.0Figure 13.0

Step 18: Press the o-ring side of the anodized blue hose connector into the coolant hardline where thefront of the EGR cooler coolant line was pressed in. Figure 14.0

Figure 14.0Figure 14.0

Step 19: Slide the open slot in the supplied bracket onto the anodized blue hose connector and put the M10 bolt through the bottom rear bolt hole and hand tighten it into the hex spacer stud. Figure 14.1

Figure 14.1Figure 14.1 Figure 15.0Figure 15.0

A

B

Step 20: Attach the supplied coolant hose to the coolant port coming off the top of the head and rout it tothe exposed end of the anodized blue coolant connector. Figure 15.0 B

Step 21: Reattach the PCV hose to the port on the valve cover and bolt the support tab to the bracket in theround hole using the supplied M10 bolt and nut. Figure 16.0 A

Step 22: Re-secure the coolant hard line tab and the exhaust back pressure hose tab to the bracket in thetwo forward holes using the supplied M8 bolts and nuts. Figure 16.0 B

Step 23: Attach the transmission dipstick tube bracket to the upper most mounting hole in the suppliedbracket using the 1/4-20 bolt and nut. Figure 16.0 C

Figure 16.0Figure 16.0

C A

B

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