The Nissan Titan XD’s 5.0L Cummins diesel engine is a powerhouse, but its Exhaust Gas Recirculation (EGR) system can sometimes cause issues. An EGR delete kit offers a solution, but commercially available kits can be expensive. This guide provides a budget-friendly DIY approach to deleting the EGR system on your Titan XD, utilizing readily available materials and basic tools. This method focuses on creating custom block-off plates and rerouting coolant lines, offering a cost-effective alternative to expensive commercial kits.
Understanding the EGR System and Deletion
The EGR system recirculates a portion of exhaust gases back into the intake manifold, aiming to reduce nitrogen oxide emissions. However, this can lead to carbon buildup, potentially impacting engine performance and longevity. An EGR delete kit eliminates this recirculation, often resulting in cleaner combustion and improved throttle response.
This DIY method involves fabricating custom block-off plates from steel to seal off the EGR passages in the intake manifold and exhaust system. It also requires rerouting coolant lines to bypass the EGR cooler. While this approach requires some mechanical skills and tools, it significantly reduces the cost compared to purchasing a pre-made kit.
Materials and Tools Required
This DIY EGR delete requires basic tools and readily available materials:
- Metal: 3/16″ thick steel flat bar (approximately 3″ wide)
- Hoses: 3/4″ ID and 3/8″ ID fuel hose (high-temp, high-pressure rated)
- Fittings: Brass tee fitting, two 90° 3/4″ brass barbs with threads, one 3/8″ barb with threads
- Fasteners: Six M8x1.25-30mm bolts and six M8x1.25 nuts, washers
- Sealant: RTV high-temperature gasket maker
- Hose Clamps: Appropriate size for the chosen hoses
- Tools: Angle grinder, bench vise, metal file, hand drill, wrenches, flexible stick magnet (recommended), measuring tools, brake cleaner
Fabrication and Installation Process
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Preparation: Drain the engine coolant and carefully remove the EGR system, intake elbow, and intake manifold. Retain the three metal EGR gaskets for tracing.
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Block-off Plate Creation: Trace the outlines of the removed EGR gaskets and the coolant line flange onto the steel bar. Cut these shapes out using an angle grinder, file any burrs, and drill the necessary mounting holes.
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Plate Installation: Clean the fabricated plates with brake cleaner. Using the M8 bolts and nuts, secure the triangular plates to their respective pipes with the original metal gaskets. Use RTV sealant on the coolant return hole block-off plate before fastening.
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Intake Elbow Modification: Measure and mark a bend line on the steel bar to create a 90° angle for the intake elbow block-off plate. Cut halfway through the line with the angle grinder, bend the steel using a vise and wrench, and flatten the bent side if necessary. Use the original gasket and RTV sealant to ensure a proper seal when attaching the plate to the intake elbow. Use washers as needed to prevent bolt bottoming.
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Coolant Line Rerouting: Cut and deburr the coolant pipes, flushing them thoroughly with water. Assemble the brass fittings and hoses to create a bypass for the EGR cooler, using Teflon tape on the pipe threads. Secure the hoses with clamps. Connect the 3/8″ hose between the tee fitting and the coolant reservoir to aid in bleeding air from the system.
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Reassembly: Reinstall the intake manifold and intake elbow, ensuring all connections are secure. After the RTV sealant has fully cured (refer to the manufacturer’s instructions), refill the cooling system and run the engine to check for leaks.
Conclusion
This DIY method provides a significant cost saving when compared to commercial Nissan Titan 5.0 Cummins Egr Delete Kits. While requiring some fabrication and mechanical aptitude, this guide offers a viable solution for budget-minded owners. Always consult the vehicle’s service manual for detailed instructions and torque specifications. Thoroughly inspect for leaks after completing the installation and address any issues promptly. Remember, modifying your vehicle may void certain warranties.
