SidesMods Australia – EGR Cooler Delete & Bypass Kits
SidesMods is an Australian manufacturer specialising in EGR cooler delete and bypass solutions for popular diesel 4WDs, utes and commercial vehicles.
Designed for Australian diesel applications, these kits replace problematic factory EGR cooler hardware with purpose-built bypass components that help remove a major source of coolant leaks, overheating and intake contamination.
Euro Car Upgrades stocks SidesMods kits for popular Ford, Mazda, Nissan, Mitsubishi and Toyota diesel platforms, with Australia-wide shipping and ECU tuning support available where required.
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Find the Right SidesMods Kit for Your Diesel
Ford Ranger & Mazda BT-50
SidesMods kits for Ranger PJ/PK, PX generations, Everest, Transit and related Mazda BT-50 diesel platforms.
PX2 / PX3 with DPF
PX2 without DPF
PX Mk1 / BT-50 UP-UR
PJ / PK / BT-50 UN
Triton, Pajero & Challenger
Australian-made EGR cooler bypass kits for Mitsubishi 4D56 and 4M41 diesel engines.
Triton ML/MN & Challenger 4D56
Triton ML / Pajero NS-NT-NW 4M41
Pajero NX 4M41
Why Remove the Factory EGR Cooler?
The EGR cooler operates in one of the toughest areas of a diesel engine: it handles hot exhaust gases while circulating engine coolant through the cooler body.
As these vehicles age, internal EGR cooler failures can allow coolant to escape into the exhaust or intake system. A serious leak can lead to coolant loss, overheating and expensive engine or cylinder-head damage.
SidesMods developed its EGR cooler bypass kits to remove this failure point completely while simplifying the EGR and cooling-system layout.
Benefits of a SidesMods EGR Cooler Delete
- Eliminates the factory EGR cooler as a potential coolant-leak failure point
- Helps prevent overheating caused by internal EGR cooler failure
- Reduces exhaust-gas contamination of the intake system
- Helps prevent heavy soot and carbon buildup in the intake manifold
- Lower intake temperatures
- Lower coolant temperatures on supported applications
- Improved engine response and efficiency
- Improved fuel economy on applicable vehicles
- Reduced soot contamination of engine oil
- Extended engine oil service life
More Than an EGR Blanking Plate
A SidesMods cooler delete kit is not simply a thin blanking plate placed into the existing system.
The kits are designed to physically remove and bypass the EGR cooler and associated plumbing on the intended vehicle. Depending on the application, the package can include purpose-built block-off components, coolant bypass hardware, hoses, fittings and the installation hardware required to simplify the system properly.
Detailed installation instructions are supplied with the kits, and SidesMods develops different configurations for different generations of the same vehicle where the factory EGR system changed.
Ford Ranger & Mazda BT-50 EGR Cooler Delete Kits
The Ranger and BT-50 family is one of the strongest parts of the SidesMods range.
There are dedicated solutions covering earlier Ford Ranger PJ/PK and Mazda BT-50 UN, the Ranger PX Mk1 / BT-50 UP-UR, and later PX2/PX3 configurations.
Later Ranger variants are split further because Ford used different EGR cooler arrangements on DPF and non-DPF engines.
Nissan Navara D40 & Pathfinder R51 YD25
The YD25-powered Nissan Navara D40 and Pathfinder R51 are well known for EGR-system contamination and EGR cooler problems.
SidesMods offers different solutions for the Euro 4 and later Euro 5 140kW layouts, including options that remove additional EGR crossover pipework.
The kits eliminate the factory cooler and help remove another common source of overheating, cylinder-head damage and intake restriction.
Mitsubishi Triton, Pajero & Challenger
SidesMods also produces EGR cooler bypass kits for some of Australia's most common Mitsubishi diesel platforms, including both 4D56 2.5L and 4M41 3.2L engines.
These engines can accumulate significant soot and carbon through the intake system, while a leaking EGR cooler introduces the additional risk of coolant loss and overheating.
Current Euro Car Upgrades applications include Triton ML/MN, Challenger PB/PC, Pajero NS/NT/NW and the later Pajero NX.
Toyota Hilux 1KD EGR Cooler Delete
The Toyota 1KD-FTV 3.0L diesel is another major opportunity for improving the EGR and intake system.
The SidesMods Hilux kit removes and bypasses the factory EGR cooler using dedicated block-off components, bypass hose and installation hardware. Removing recirculated exhaust contamination helps keep the intake cleaner while eliminating the EGR cooler from the cooling circuit.
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Complete the Job Properly
ECU EGR Calibration
On many modern diesel vehicles, mechanically removing or blanking the EGR system also requires the ECU strategy to be recalibrated.
Euro Car Upgrades can supply the hardware while our technical team can provide ECU-level EGR calibration for suitable off-road, competition and agricultural applications.
Clean Out the Carbon Already There
Deleting the cooler stops future EGR contamination, but it does not remove the years of soot already accumulated inside the intake manifold, throttle body and associated pipework.
An intake clean performed at the same time restores airflow and lets the engine start with a clean intake system.
Australian-Made Diesel Solutions
SidesMods products are manufactured in Australia and developed around diesel vehicles that are common on Australian roads, worksites and off-road tracks.
The range focuses on practical solutions to common factory-system problems rather than universal one-size-fits-all hardware. Different generations, engines and emissions-system layouts receive different kits so the supplied components match the application.
For Euro Car Upgrades, that makes SidesMods a particularly good fit: practical Australian hardware for vehicles that owners want to keep working, towing and performing reliably.
Frequently Asked Questions
What does an EGR cooler delete kit do?
An EGR cooler delete or bypass kit removes the factory EGR cooler and redirects the coolant circuit using purpose-built bypass components. This removes the cooler as a potential source of internal coolant leaks while simplifying the EGR system.
What are the benefits of a SidesMods EGR cooler delete?
SidesMods lists benefits including eliminating EGR cooler leak risk, helping prevent overheating and engine damage, reducing intake carbon contamination, lowering intake and coolant temperatures on applicable vehicles, improving fuel economy and extending engine oil life.
Are SidesMods kits made in Australia?
Yes. The SidesMods products stocked by Euro Car Upgrades are Australian-made diesel performance and reliability components.
Is an EGR cooler delete the same as fitting a blanking plate?
No. A blanking plate simply blocks a gas passage while leaving most of the original EGR hardware in place. A SidesMods cooler delete kit physically removes and bypasses the EGR cooler and associated components for the intended application.
Do SidesMods kits include everything required for installation?
Yes. SidesMods supplies its application-specific kits with the components required for the cooler removal/bypass together with detailed installation instructions. Exact kit contents vary by vehicle.
Do I need an ECU remap after installing an EGR delete kit?
It depends on the vehicle and the specific kit. Some SidesMods applications are designed to stop EGR operation without fault lights while retaining the relevant factory ECU tables. Other modern vehicles require ECU recalibration so the EGR strategy is correctly disabled.
Where ECU calibration is required, Euro Car Upgrades can supply the appropriate hardware and ECU tuning solution.
Why should I clean the intake manifold at the same time?
Years of EGR operation can leave substantial soot and carbon deposits inside the intake manifold. Removing the EGR cooler prevents future contamination but does not remove deposits that are already there.
Cleaning the intake during the installation restores airflow and allows the engine to benefit fully from the modified EGR system.
Which Ford Ranger EGR delete kit do I need?
SidesMods produces different kits for Ranger PJ/PK, PX Mk1, PX2 and PX3 applications. Later PX engines also use different EGR cooler arrangements depending on emissions specification and whether the vehicle is equipped with a DPF.
Choose the product that matches your Ranger generation, engine and EGR cooler configuration.
What is the difference between the Navara D40 Euro 4 and Euro 5 kits?
The YD25 EGR system changed between Euro 4 and Euro 5 engines. Euro 4 vehicles use the earlier cooler arrangement, while the later 140kW Euro 5 engine uses a different cooler mounted above the exhaust manifold.
SidesMods supplies dedicated kits for both versions, with additional crossover-pipe options available on selected applications.
Can an EGR cooler leak damage the engine?
Yes. An internal EGR cooler leak can result in coolant loss and overheating. SidesMods specifically promotes eliminating this failure point as one of the main reasons for fitting its cooler bypass kits.
Can I install a SidesMods kit myself?
Many SidesMods kits are supplied with detailed instructions and can be installed by someone with suitable mechanical experience. Installation time and difficulty vary significantly by vehicle, and some later Ranger and Navara applications require several hours because of the EGR cooler location.
Are SidesMods EGR delete kits for road use?
SidesMods identifies these EGR-delete products as designed and tested for off-road use. Removing or disabling emissions-control equipment can affect road-vehicle compliance, so these products should be used only in applications where the modification is permitted.
Does Euro Car Upgrades ship SidesMods products Australia-wide?
Yes. Euro Car Upgrades supplies SidesMods products Australia-wide, with current availability and dispatch information shown on each product page.






