Home » 2007.5-2024 6.7L Dodge Ram Cummins Diesel EGR Delete Kit

Compatibility: 2007.5–2009 Dodge Ram 2500 / 3500 (6.7L Cummins Diesel)

Product: EGR Valve & Cooler Delete Performance Kit

LEGAL DISCLAIMER & COMPLIANCE

OFF-ROAD USE ONLY: This high-performance racing component is engineered exclusively for competition or sanctioned off-road use. It does not comply with federal or local emissions laws for highway operation. Installation on any vehicle registered for public roads is strictly prohibited. The end-user assumes all legal liability and risk associated with the installation and use of this product.

PHASE 1: PREPARATION & TOP-SIDE DISASSEMBLY

Step 1: Engine Cover Removal Remove the plastic engine shroud by extracting the four (4) 8mm bolts.

  • Note: The oil dipstick must be pulled out temporarily to allow the cover to be removed from the engine bay.

Step 2: Crossover Pipe Extraction

  1. Loosen the two (2) V-band clamps using an 11mm socket.

  2. Remove the 10mm center mounting bolt and disconnect the sensor harness plug.

  3. Remove the EGR crossover pipe and disconnect the electrical connector from the EGR valve.

Step 3: EGR Valve Removal Identify the locking plates on the electrical connectors; slide them to the "unlocked" position before disconnecting. Remove the four (4) 10mm bolts securing the EGR valve and lift the unit from the intake manifold.

PHASE 2: INTAKE & THROTTLE MANAGEMENT

Step 4: Surface Preparation & Throttle Isolation

  1. Contamination Control: Thoroughly clean all existing gasket material from the intake elbow mounting surface.

    • CRITICAL: Place clean shop rags inside the open ports to prevent debris from falling into the air intake.

  2. Throttle Valve: Locate the throttle valve on the driver’s side, directly below the intake elbow. Disconnect the electrical harness.

    • Tech Tip: To prevent the valve from failing in the closed position, it must be removed or electronically disabled.

Step 5: Block-Off Installation & Heat Shields

  1. High-Flow Option: Installing a throttle valve delete pipe is recommended for increased intake airflow.

  2. Intake Seal: Install the new intake block-off plate using the provided bolts. Ensure both O-rings are seated perfectly in their grooves to prevent boost leaks.

  3. Shielding: Remove the heat shield from the EGR bypass valve by removing the three (3) 10mm nuts and two (2) 8mm bolts.

PHASE 3: EGR SERVO & COOLER EXTRACTION

Step 6: Bypass & Servo Removal

  1. Remove the four (4) 10mm bolts securing the exhaust bypass.

  2. Remove the five (5) 10mm bolts securing the EGR servo mounting bracket.

Step 7: Cooler Disconnection

  1. Simultaneously extract the EGR servo (on its bracket) and the exhaust bypass.

  2. Remove the crankcase breather tube. Disconnect the two (2) coolant lines from the EGR cooler.

    • Note: Ensure the factory O-ring is removed from the engine block fitting.

  3. Remove the four (4) 10mm cooler mounting bolts and the two (2) 15mm nuts at the exhaust manifold near the firewall.

  4. Release the V-band clamp connecting the cooler to the exhaust crossover elbow.

Step 8: Crossover Elbow Block-Off Remove the exhaust crossover elbow (secured by two 15mm nuts). Install the solid exhaust block-off plate (without the pre-drilled port) in this location.

PHASE 4: FINAL BRACKETING & SEALING

Step 9: Support Bracket Removal

  1. Relieve any remaining cooling system pressure at the reservoir.

  2. Remove the four (4) main cooler nuts and pull the EGR cooler up and out toward the front of the vehicle.

  3. Unbolt the two (2) 14mm bolts to remove the heavy EGR cooler mounting bracket from the engine block.

Step 10: Exhaust Manifold Sealing

  1. Install the second exhaust block-off plate (the one with the pre-drilled port) onto the rear of the exhaust manifold using factory hardware.

  2. Re-install the crankcase breather tube.

Step 11: Support Bracket Integration

  1. Secure the provided support bracket to the head mounting hole previously occupied by the cooler bracket (located behind the vertical coolant pipe).

  2. Connect the dipstick tube and the coolant line bracket to the other end of the new support bracket using the provided hardware. This ensures all components remain rigid and vibration-free.

PHASE 5: REASSEMBLY & TESTING

Step 12: Final Commissioning

  1. Refill the cooling system with approved HOAT coolant.

  2. Start the engine and allow it to reach operating temperature.

  3. Inspection: Carefully check for any signs of coolant, oil, or exhaust leaks. Top off the coolant reservoir as needed once the system has purged all air.

POST-INSTALLATION ADVISORY

  • ECM Tuning: This hardware modification requires a compatible Race Tune (e.g., EFI Live or H&S) to disable the EGR logic and prevent Check Engine Lights (CEL).

  • Maintenance: Re-torque the exhaust manifold block-off hardware after the first 100 miles of operation.