Sinister Diesel Complete Solution® Kit with Blue EGR Cooler
Fits 2003–2007 Ford Powerstroke 6.0L
Key Features
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Eliminates the most common 6.0L Powerstroke failures (head gaskets, EGR cooler, oil cooler)
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Includes Sinister Diesel’s upgraded Blue EGR Cooler with durable internal tube design
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Heavy-duty upgraded oil cooler improves cooling efficiency and reliability
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ARP Head Studs prevent head gasket failure under high load
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All factory Ford gaskets, turbo hardware, and O-rings included for a complete install
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Backed by proven components from the best names in the diesel industry
Failure Symptoms – Do You Need This Kit?
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White smoke from the exhaust (EGR cooler failure)
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Overheating or high engine oil temps (oil cooler restriction)
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Coolant loss with no visible leaks
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Blown or leaking head gaskets
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Hard starts, poor performance, or repeated trips to the shop
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Tired of patchwork repairs instead of a permanent fix
Reasons to Upgrade
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Stop worrying about stretched bolts, blown head gaskets, and failed EGR coolers
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Restore confidence and reliability in your 6.0L Powerstroke
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Save time and money by getting everything in one complete kit
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Extend engine life with improved cooling and sealing
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Prevent costly downtime and repeat repairs with long-term proven solutions
2003–early 2006 6.0L Powerstroke engines used 18mm dowel head gaskets. Builds after January 2006 and all 2007 models used the larger 20mm dowel pins included in this kit. Some earlier trucks may have been updated with newer cylinder heads, so please verify dowel size before ordering to ensure proper fitment. If you need 18mm head gaskets, use this kit: 18mm Complete Solution Kit
Product Description
The Sinister Diesel Complete Solution® Kit with Blue EGR Cooler is the ultimate fix for the 6.0L Powerstroke’s most notorious problems. Designed as an all-in-one package, this kit eliminates weak points in the factory design, ensuring your truck runs stronger and longer.
At the heart of the kit is our Blue EGR Cooler, featuring a unique internal tube design that delivers superior cooling capacity and durability compared to the failure-prone factory fin-style cooler. Paired with an upgraded heavy-duty oil cooler, you’ll see improved oil flow and reduced temperatures, which extend engine life and prevent future breakdowns.
To address the head gasket issue, the kit includes ARP Head Studs. Unlike the factory bolts that stretch and allow gaskets to fail, ARP studs provide unmatched clamping force, keeping your cylinder heads sealed tight even under heavy load or tuned conditions.
With everything you need included—gaskets, turbo hardware, O-rings, and premium components—you can get the job done right the first time without chasing extra parts.
Why Buy From Sinister Diesel?
Sinister Diesel has built its reputation by engineering upgrades that solve real-world Powerstroke problems. Each Complete Solution® Kit is carefully curated with the highest-quality components, tested for durability, and backed by our support team so you can install with confidence. When you choose Sinister, you’re not just buying parts—you’re investing in proven reliability.
What’s Included
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SD-CS-6.0 – Complete Solution® Kit
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Sinister Diesel Blue EGR Cooler (Square Style, SD-EGRC-6.0-04)
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Upgraded Oil Cooler
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Updated Oil Cooler Screen
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Oil Cooler Gasket Kit
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ARP Head Studs with lubricant
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20mm Black Diamond Head Gaskets
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Factory Ford Intake Gasket
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Factory Ford Turbo Hardware & O-Ring Kit
