EGR Delete Plug Kit Stage 1 Plates and Plugs For Cummins ISX CM870 2002-2007 Stage 2

Here’s the detailed technical breakdown for the EGR Delete Plug Kit (Stage 1 Plates & Plugs) for Cummins ISX CM870 (2002-2007) engines, including critical installation, tuning, and legal considerations:

🔧 Kit Contents & Specifications

⚠️ Critical Fitment Notes

• Engine Compatibility:
  ✅ 2002-2007 Cummins ISX CM870 (STAGE 2 engines only)
  ❌ Does NOT fit:

  • CM871 (2007+ with DPF)

  • ISX15 (2010+)

  • Any EPA 2010+ compliant engines

• Visual Identification:

  • Stage 2 ISX has a round EGR valve mounted on the intake horn

  • CM871+ has a square EGR module near the turbo

🛠️ Installation Requirements

Tools Needed:

• Torx T40 (EGR valve bolts)

• 13mm & 15mm sockets

• High-temp RTV sealant (Permatex Ultra Copper recommended)

• Torque wrench (22-25 ft-lbs for plate bolts)

Key Steps:

1. Coolant System Prep:

   • Drain coolant below the thermostat level

   • Cap open lines with included plugs

2. Sensor Management:

   • Leave EGR temp sensor plugged in but secured away

   • Retain all other emissions sensors

3. Plate Installation:

   • Apply RTV to both sides of plates

   • Torque bolts in criss-cross pattern

⚡ Performance Impact

Expected Gains:

• 3-5% improved fuel economy

• Extended valve/turbo life (no soot abrasion)

• Lower EGTs (by 150-200°F under load)

🚨 Legal & Warranty Consequences

Dealer Impact:

• ECM stores permanent “Emissions Tamper” flag

• Voids all emissions-related warranties

💻 Mandatory Tuning

Without Tuning:

• Derate to 5mph within 50 miles

• Fault Codes: P0401-P0406, P0299 (boost leaks)

• Regen system malfunctions

Recommended Tuners:

• EFI Live (w/ CSP5 switch) – Best for custom tuning

• Smarty S-67 – Pre-loaded delete tunes

• H&S XRT Pro – For real-time adjustments

Parameters to Modify:

• Zero out EGR valve position tables

• Disable EGR cooler monitoring

• Adjust MAF scaling for cleaner airflow

🔩 Supporting Mods

1. Cold Air Intake (S&B 75-5075)

2. Boost Leak Fix Kit (BD Diesel 1037201)

3. EGT/Boost Gauges (Edge CTS3)

🛑 Legal Alternatives

For trucks needing compliance:

• Cummins #4926887 – EGR service kit

• Pacbrake EGR Cleaner – CARB-legal maintenance solution