You HAVE to follow these instructions in order to gain a code free EGR / DPF delete and see the full power
potential !
Using the EGR /DPF off option on a stock truck will result in severe engine and exhaust system damage!
The late injection events ( formerly know as the 4th injection ) are turned OFF! Thus NO regeneration
can take place even if the ECM commands it! The DPF will plug and result in excessive back pressure!
Required exhaust modifications :
- The DPF and catalyst(s) need to be replaced with an after market exhaust system.
- Starting from software revision “V:6.09A D:R12ME” the original exhaust gas temperature thermocouples are no
longer needed! You can simply unplug them and seal the OEM connectors in the wiring harness with electrical
tape.
If you already use thermocouple simulators ( “SIMS” ) you can eventually leave them in place but we HIGHLY
recommend to remove them! We have found a wide variety of problems caused by out of spec / faulty / false
contacts SIMS. Thus it is best to remove them!
- The oxygen sensors are not needed ( can be unplugged ) but if you have an exhaust system that already has the
provision for these probes they can remain plugged in and used.
- The exhaust differential pressure sensor ( on the top of the transmission, passenger side ) has to remain plugged
into the factory harness but the rubber lines coming from the stock exhaust have the be unplugged from the sensor.
Required EGR / Throttle valve / EGR Cooler modifications :
There are two possible ways to delete the components in the engine bay.
- Disconnect only the throttle valve connector and block of the EGR. In this case all other connectors and
components can remain in place.
- Remove the EGR system entirely. Then all components, EXCEPT the EGR actuator motor, can be unplugged and
taken off.
The EGR is disabled and can be disconnected without generating codes. YET!!!!!!, unplugging the EGR will throw
the engine in a limp mode thus about 40Hp are lost, The actuator motor of the EGR valve should remain
connected in order to see the full power gain of these softwares!
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Engine overview
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The EGR actuator motor can be easily taken off of the EGR
valve assembly
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With the key in the OFF position, remove the 4 screws of the EGR
actuator motor
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Pull off the EGR actuator motor and turn key to run position, do
not start engine
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With the key in the run position the actuator will move out.
Gently pull the actuator out of the motor.
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Now you can zip tie the connected EGR actuator motor to any
convenient location.
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You can either take off the OEM EGR valve assembly and block
off the ports in the intake or replace the whole OEM intake with an
after market unit.
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The throttle valve connector needs to be unplugged. The
connector is on the back side of the assembly and difficult to see
and get to. The easiest way to find the correct connector and
correct removal angle is from below the engine. ATTENTION!
There is a lock tab in the connector that must be moved sideways
in order to remove the connector!
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For convenience, a close up of the complete intake seen as from
the front of the engine.
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For convenience, a close up of the complete intake as seen from
the back of the engine. The throttle valve connector is clearly
visible.
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Unplug the EGR cooler servo assembly.
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A few words about eventual DTC's that may come up for some time after the EGR / DPF delete.
It can happen that codes show up for some while after the conversion has been completed. That's because the ECM
needs to run the whole DTC routines in order to completely erase those codes. How long it will take for those codes
to disappear depends upon in which point of the DTC detection routine the ECM is when the conversion is
performed. After driving the truck for some while the code(s) normally will then disappear on their own. We have
seen as little as a few seconds and as long as a couple hours driving. In a few cases it may be required to erase the
codes with the Smarty. This is due to the fact that the ECM runs two distinct DTC detection routines which are not
synchronised. Depending upon where they are when the conversion is done...
Also it is important to notice that the truck has to be DTC free when the conversion is done! It can happen that a
code for example low fuel pressure also brings up an EGR code. That is because the ECM may check several
circuits at one time when a DTC is detected. We have blocked only the direct detection of the EGR / DPF DTC's In
order to retain a fully operational DTC detection for all other engine components.
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Download Smarty S67ME update file
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