Performing an EGR delete on a Cummins ISX15 or X15 engine requires precise installation of an EGR cooler bypass tube to maintain proper coolant flow and engine performance. Follow this detailed step-by-step guide to correctly install our EGR cooler bypass kit (part numbers 4367122 and 5575183), which includes all necessary components for a seamless upgrade.
Step 1: Preparation and Safety
✔ Disconnect Batteries – Before starting, disconnect both positive and negative battery terminals to ensure safety.
✔ Drain Coolant – Completely drain the cooling system to prevent spills when removing components.
Step 2: Turbo and Exhaust System Removal
✔ Remove Turbo Connections – Disconnect the intake and exhaust piping connected to the turbo.
✔ Remove the Turbocharger – Carefully remove the turbo to access the EGR and exhaust components.
✔ Remove the Exhaust Manifold – Unbolt the exhaust manifold and set it aside for reinstallation later.
Step 3: EGR System Removal
✔ Remove the EGR Cooler – Detach the EGR cooler from its mounting location.
✔ Remove the EGR Valve – Take out the EGR valve, which is no longer needed after the bypass.
✔ Remove the EGR Piping – All related EGR pipes and tubing must be removed.
Step 4: Installing the EGR Cooler Bypass Tube
✔ Install the Exhaust Manifold Elbow – The exhaust manifold end at cylinder #1 is removed and replaced with the elbow included in our kit.
✔ Reinstall the Exhaust Manifold – Secure the exhaust manifold back in place using new gaskets provided in the kit.
✔ Modify and Install the Exhaust Gas Pressure Sensing Line – This line is modified and installed into the new exhaust elbow using the special fitting included in the kit.
✔ Install the EGR Transfer Tube – The EGR cooler bypass tube (part numbers 4367122 and 5575183) is installed in place of the removed EGR cooler, ensuring proper coolant flow.
✔ Attach the Turbo Actuator Coolant Return – Secure the actuator coolant return line using the new tubes provided in the kit.
✔ Install the EGR Crossover Block-Off Plate – The EGR crossover is not reinstalled. Instead, a block-off plate from the kit is installed in its place to seal the system.
Step 5: Final Checks and Coolant Refill
✔ Perform a Leak Test – Inspect all connections, fittings, and gaskets for leaks before proceeding.
✔ Refill Coolant and Pressure Check – Fill the system with coolant, pressurize the system, and check for any leaks to ensure a proper seal.
✔ Reconnect Batteries and Final Inspection – Reconnect the batteries and perform a final inspection to confirm all components are secured and properly installed.
Upgrade Your Engine with Confidence
Our EGR cooler bypass kit (part numbers 4367122 and 5575183) includes all necessary components for a successful installation, ensuring proper coolant flow, improved engine performance, and long-term reliability.
By following this guide, you ensure a professional-grade installation, eliminating the risk of EGR cooler leaks while maintaining the intended function of the Cummins ISX15 and X15 cooling system.
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