Home » 2010-2024 6.7L Ram Cummins 2500 3500 EGR Valve Cooler Delete Kit

Compatibility: 2010–2024 RAM 2500 / 3500 (6.7L Cummins Diesel)

Product: Complete 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: TOP-SIDE DISASSEMBLY

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

  • Note: The oil dipstick must be pulled out temporarily to allow the cover to clear 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.

  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 manifold.

PHASE 2: INTAKE & THROTTLE MANAGEMENT

Step 4: Intake Preparation

  1. Contamination Control: Scrape away all old gasket material from the intake elbow 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: The throttle valve must be removed or disabled to prevent it from permanently closing once the EGR system is deleted.

Step 5: Intake Blocking & Heat Shields

  1. Performance Option: For maximum airflow, install a dedicated throttle valve delete pipe in place of the factory unit.

  2. Block-Off: Install the new intake block-off plate using the provided hardware. Ensure the O-rings are seated perfectly in their grooves.

  3. Heat Shield: Remove the insulation board/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.

  3. Simultaneously extract the EGR servo and the exhaust bypass from the engine bay.

Step 7: Cooler Disconnection

  1. Remove the crankcase breather tube running across the EGR cooler.

  2. Disconnect the two (2) coolant lines. Ensure the factory O-ring is removed from the engine block fitting.

  3. Remove the four (4) 10mm cooler mounting bolts.

  4. Remove the two (2) 15mm nuts connecting the cooler to the exhaust manifold near the firewall.

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

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

PHASE 4: FINAL BLOCK-OFF & COOLANT BYPASS

Step 9: Support Bracket Removal

  1. Relieve any remaining cooling system pressure.

  2. Remove the four (4) main cooler nuts and lift 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 back side of the exhaust manifold using factory hardware.

  2. Re-install the crankcase breather tube.

  3. Insert the provided black performance coolant hose into the coolant port.

Step 11: System Securing Secure both ends of the new coolant hose at the interfaces. Use a wrench to tighten all brackets and ensure all wiring harnesses and sensors are re-secured with the original screws to prevent vibration damage.

PHASE 5: REASSEMBLY & TESTING

Step 12: Commissioning

  1. Refill the cooling system with approved OAT coolant.

  2. Start the engine and allow it to reach operating temperature until the coolant circulates through the new bypass hose.

  3. Inspection: Carefully check for any signs of coolant, oil, or exhaust leaks. Top off the reservoir as needed.

POST-INSTALLATION ADVISORY

  • ECM Tuning: This hardware modification requires a compatible Race Tune (e.g., EZ LYNK or EFI Live) to disable EGR logic and the throttle valve.

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