HOW TO REMOVE EGR COOLER 6.7 CUMMINS
STEP-BY-STEP GUIDE TO DPF, EGR, AND DEF DELETE FOR CUMMINS ENGINES
If you’re looking to improve the performance, fuel efficiency, and longevity of your Cummins engine, a DPF, EGR, and DEF delete is a popular solution. This guide will walk you through the process of removing these emissions systems, ensuring your engine operates at its full potential. Whether you own a 6.7 Cummins or another model, this step-by-step guide will help you achieve optimal results.
What You’ll Need:
Before starting, gather the following tools and materials:
- DPF EGR DEF delete kit (cummins isx egr block off plate)
- Socket set and wrenches
- Screwdrivers
- Safety gloves and goggles
- Laptop (for ECM reprogramming) (how to delete egr from ecu)
- Reliable tuning service (like DPF Delete Shop for remote ECM tuning)
- Nexiq 2 adapter or any other that complies with the RP1210 protocol
ECM REPROGRAMMING ADAPTERS
NEXIQ USB Link 2
• Description: One of the most widely used adapters in the industry, compatible with a wide range of trucks and systems.
• Protocols: RP1210, J1708, J1939, J1587.
• Connectivity: USB.
• Compatible Brands: Cummins, Detroit, Volvo, Mack, Freightliner, International, Peterbilt, Kenworth, and more.
• Applications: Diagnostics, ECM programming, real-time monitoring.
Cummins INLINE Adapter
• Description: Official Cummins adapter for your INSITE software, compatible with the RP1210 protocol.
• Protocols: RP1210, J1939, J1708.
• Connectivity: USB.
• Compatible brands: Cummins.
• Applications: Diagnostics, calibration, real-time parameter monitoring.
JPRO Professional Adapter
• Description: Noregon adapter, designed for use with JPRO software, compatible with RP1210.
• Protocols: RP1210, J1939, J1708.
• Connectivity: USB.
• Compatible brands: Cummins, Detroit, Volvo, Mack, Freightliner, International, Peterbilt, Kenworth.
• Applications: Full diagnostics, module programming, software updates.
ECM Reprogramming
Begin by reprogramming the Engine Control Module (ECM) to deactivate the DPF, EGR, and DEF functionalities. It is important that this process is done by people trained in the subject. Contact us, so we can help you with the ECM reprogramming. Our ECM tuning will allow you to lock the EGR valve and disconnect all EGR sensors. Professional ECM tuning ensures the engine operates optimally without triggering fault codes or entering limp mode.
LIST OF ALL OUR DELETE TUNES FOR CUMMINS ENGINES.
Physical Removal of DPF
- Extract the DPF Unit: Detach the DPF from the exhaust system.
- Install a Straight Pipe: Replace the removed DPF with a straight pipe to maintain exhaust flow.
- Disconnect Sensors: Unplug all sensors associated with the DPF, including temperature and pressure sensors, to prevent erroneous readings.
How to eliminate EGR valve
EGR System Deactivation
Block Off EGR Pathways: Install block-off plates at both the intake and exhaust junctions of the EGR system to prevent exhaust gases from recirculating.
How to remove a EGR valve: Steps to follow
The steps to block the EGR are the same on all Cummins engines.
The EGR must be blocked with steel plates on both the cold and hot side.
The first blocking plate goes in the position where the EGR manifold meets the exhaust manifold.
The second blocking plate goes in the position where the EGR manifold meets the intake manifold.
For the best engine performance, we always recommend blocking the EGR on both the cold and hot sides.
INTAKE SIDE BLOCKAGE (COLD): The air volume and the geometry of the intake manifold will not be affected by the EGR tubes.
EXHAUST SIDE BLOCKAGE (HOT): The geometry of the exhaust manifold will be returned to the factory one.
Example of the position of the EGR hot side plate
(photo taken from a CM2250/CM2350/CM2350A X15 ISX engine) All other cummins engines are almost the same( CM871, CM2150D, ISL, ISC, ISB, ISM)
Cummins CM2250/CM2350/CM2350A X15 Engine Exhaust Side Block Off Plate Location
Example of the position of the cold side (intake) EGR plate.
Cummins CM2250/CM2350/CM2350A X15 Intake Side Block Off Plate Location
Unplug EGR Valve Connector: Disconnect the electrical connector from the EGR valve to disable its operation.
Cummins CM2250/CM2350/X15 EGR Valve Electrical Connector Location
Disconnect EGR Sensors: Unplug sensors related to the EGR system, such as the differential pressure sensor and temperature sensor, to avoid false signals.
EGR sensor locations on CM2250/CM2350/CM2350A X15 ISX.
Cummins CM2250 EGR Differential Pressure Sensor Location
/CM2350/X15 EGR Temperature Sensor Location Cummins CM2250/CM2350/X15
How to delete def system
DEF System Decommissioning
Drain DEF Tank: Empty the DEF tank to prevent any residual fluid from being injected into the exhaust.
Disable DEF Injector: Disconnect the DEF dosing valve to stop the injection of DEF into the Selective Catalytic Reduction (SCR) catalyst.
Unplug DEF Sensors: Disconnect sensors monitoring DEF quality, level, and temperature to prevent system errors.
Post-Removal Inspection
Verify System Integrity: Ensure all block-off plates are securely installed and there are no exhaust leaks.
Check for Diagnostic Trouble Codes (DTCs): Use a diagnostic tool to confirm that no DTCs are present after the modifications.
Test Drive: Conduct a thorough test drive to ensure the engine operates smoothly and that performance has improved as expected.
Conclusion:
By following this guide, you can successfully remove the DPF, EGR, and DEF systems from your Cummins engine, leading to enhanced performance and reduced maintenance. Always ensure that such modifications are permissible in your area and understand the environmental implications of these actions.