blmyachtsales

trying to read this sticky and don't see anything. Sure I am doing something wrong. Can somone help

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2010 crew cab 2500, G56, red st, no carpets, no cloth! no mods yet.

04SSHD

Moving this over... (cummins 1ton is a member over here as well)

Good write up Matt

Here is some quick static from me - I'll keeping adding stuff as I have time.

First off... RESULTS WILL VARY BY ECM FLASH Cummins 1ton is on AX and I'm on AG both 07.5 trucks.

To keep the factory muffler and tailpipe you'll need about 4'8" of 4" exhaust pipe.

Parts sources...

4" (and 5") exhaust pipe can be found online here (for a price) Aluminized Steel Tubing 4" OD X 60"

Shibby Engineering (Forum Member Shibbyutman) has 4" exhaust flanges that will work with th above pipe.

EGT plugs are part number 5013959AA and can be purchased for $9 and some change (plus shipping) from some the online MOPAR parts sites, also check with your favorite forum vendor, many are offering EGT Sims already made at a good price.

02 Sensor bungs can usually be found at exhaust shops, I believe they are 18x1.5mm.

The above mentioned resistors (330ohm) can be purchased from Radio Shack and other electronics stores however you might have to buy the $6 grab bag of resistors to get them if they don't have them in the 5 packs.

Things that you will need to figure out -

Some type of hanger system between the factory mounts and the delete pipe.

A bolt (or plug) to plug the EGT sensor hole left over in the downpipe - the thread pitch is 12x1.25mm

This is what the exhaust system looks like from the turbo to muffler with all of the sensors labeled.



This is what our DIY DPF delete should look like (minus the bad paint job)



Here are the stock components as they are installed on the truck. (QCSB)

Downpipe to CAT.



CAT to DPF



DPF to Muffler.



DPF Pressure Tubes Pic 1



Electrical Connections
EGT#1 and O2#1

02#2

EGT#2

EGT#3


EGT SIMS

There are many different ways of making these, the general idea is to get a 330ohm resistor across the pins of the EGT sensor plug that goes toward the factory harness.

This is a factory EGT probe and connector



This is the ~$9 connector kit that can be purchased.



This is one of the many flavors of EGT sim



It can also be done like this.



When installed on the truck they look like this.



Here is a thread on disassembling the factory sensor connectors for those who want to go that route.

http://www.cumminsforum.com/forum/6-...sassembly.html

3 1/2 watt 330 ohm resistors are required for this, resistor tolerance (gold band) is unimportant in my opinion however the first 3 colors must match the picture below and must be in the same order



This value of resistor will show somewhere between 1220 - 1240 degrees of EGT to the ECM.

With a MSD Dashhawk or Edge Insight type monitor the EGT values should read ~1220 degrees with the EGT sims working correctly.



DPF Pressure Sensor

This is where things get froggy and one has to experiment to figure out what works for their truck.

Generally when using a code clearing device such as the Edge J/A or PMT the pressure sensor should be left electrically connected but with the hoses removed like this.


This is how I run with the old AG flash on my 07.5, I've run hundreds of mils without clearing codes and I've never seen a CAT FULL message or gone into derate mode.

Resist the temptation to connect the ports together as it can cause problems, if dirt is a concern hoses can routed up with little filters installed on the ends.

The 2nd way to do this is to unplug the sensor electrically (if you do this it really doesn't matter what you do with the physical ports) cover both connections with something to keep the elements out.



The downside to doing this is that it creates a 'hard code' that cannot be cleared with any of the usual code clearing mechanisms. It has been suggested that this might eliminate the CAT FULL messages and dinging on later flashes but will leave a constant CEL, I don't believe this will cause a derate.

Now for the DPF pressure fooler - this has allowed for 'code free' DPF delete operation on some trucks that do not have the EGR deleted, this has also eliminated the overhead CAT FULL messages and constant dinging on some trucks but the success of this mod seems to be related to which version of flash one has.

Parts required -

qty 1 390 ohm resistor 1/2 watt
qty 1 110 ohm resistor 1/2 watt

These can usually be found at Radio Shack but you might have to get the $6 grab bag of resistors to find them; if you got the grab bag for the EGT sim resistors then these values are probably in the bag.

Resistor color codes -

(The first 3 bands are most important and must match the pictures below) some have said that a 100 ohm will work in place of the 110.


Wiring -

Viewed as the plug is facing you while looking up at it.



One must be creative when wiring this in, several folks on here are trying to source the connectors so that this can be done the correct way.

CODES

Here is a summary of codes that I've seen with my DIY DPF delete - to the best of my knowledge these are harmless and they are all capable of being cleared with a code clearing box.

P2080-EXHAUST GAS TEMP SENSOR CIRCUIT PERFORMANCE - BANK 1 SENSOR 1
P2084-EXHAUST GAS TEMP SENSOR CIRCUIT PERFORMANCE - BANK 1 SENSOR 2
P242B-EXHAUST GAS TEMP SENSOR CIRCUIT PERFORMANCE - BANK 1 SENSOR 3 - DIESEL

These are sporadic, I'm certain that my connections are good and thus far the only thing I've come up with is that my ECM gets cranky when it see fixed EGT values that don't change with engine warm up. I've datalogged the EGT sensors when these codes occur and haven't seen anything that points to faulty connections as the culprit.

P244A-DIESEL PARTICULLATE FILTER DIFFERENTIAL PRESSURE TOO LOW
P2453-DIESEL PARTICULATE FILTER PRESSURE SENSOR A CIRCUIT PERFORMANCE

Both of these are regular codes for me, I assume they are because the DPF pressure sensor never changes since the ports aren't connected. I am NOT running a DPF pressure fooler (yet) so I don't know if using one would eliminate these codes.

P2454-DIESEL PARTICULATE FILTER PRESSURE SENSOR A CIRCUIT LOW

This code only came up when the DPF pressure sensor was electrically disconnected, it could not be cleared with a code clearing box and did not appear to derate the engine in anyway.

The following are bad codes and mean that an engine derate has occurred as a result of something not working correctly with the delete system.

P242F-DIESEL PARTICULATE FILTER RESTRICTION - ASH ACCUMULATION
P1451-DIESEL PARTICULATE FILTER SYSTEM PERFORMANCE

Generally these codes cannot be cleared with a standard scan tool, in some cases reinstallation of the DPF system and a long highway drive (enough distance for a successful regen to be performed) have cleared these codes and underated the engine.

EGR Delete

Pictures of the basic components, I'll add comments later.

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Rockwerx

Wasn't the budget EGR delete just installing a flat frost plug (under 2 dollars) in the EGR tube? I used a dish shapped one on a 6.7 but then you also have to take the tube off (and the EGR mixer valve) and block off the EGR valve on the air horn (you could also put some thin plates under the mixer valve).

powerfun

on the egr delete do the cooler and throttle body need to be unplugged ?

Tucky

Hey guys im new just wondering if any one could help me out a little I just eliminated my exhaust using the instructions on this fourm with the resistors and im getting a p244a code (Deisel particullate filter Differential press to low) Will this hurt the truck to stay on or is there a way i can get rid of it cheap

Rockwerx

Some trucks respond to the resistor tricks and some do not...it may depend on what flash a truck has. Did you use the 110-330 resistors on the pressure differential sensor? If so, try checking your connections again to be sure they are correct. I am not sure if there is a cheap patch for all trucks.