Installation Instructions

Cummins ISX CM871 – Stage 1 EGR Plug Kit

Step 1

Remove the EGR pipe from the intake manifold on the driver side of the engine.
Remove three (3) 13 mm bolts.
(Refer to the illustration below.)

Step 2

Clean the mating surface on the intake manifold thoroughly.
Install the copper block-off plate between the intake manifold and the EGR pipe.
Install and tighten the bolts securely.

After installation, start and warm up the engine, then re-torque the bolts securing the copper plate.

Step 3

On the passenger side, remove the intake pipe leading to the turbocharger to access the V-band clamp connecting the EGR cooler to the exhaust manifold.
Use a 10 mm deep socket.

Step 4

Once the V-band clamp is removed, use a flat screwdriver to carefully remove the gasket.
Install the new gasket supplied with the kit and insert the round block-off plate between the mating surfaces.
Reinstall and secure the V-band clamp.
(Refer to the illustration below.)

Step 5

EGR cooler coolant supply plugs are not required if the EGR cooler is not leaking coolant.
If the EGR cooler is leaking coolant, continue with the following steps.

Step 6

Remove the coolant line located on top of the thermostat housing.
Install the coolant plug supplied in the kit.
(Refer to the illustration below.)

Step 7

Locate the coolant line running from the oil cooler to the 7th injector, positioned behind the turbocharger.
Remove this line and install the plug provided in the kit into the oil cooler housing.
(Refer to the illustration below.)

Step 8

Locate the coolant elbow below the EGR cooler on the rear side of the engine.
Remove the two (2) 13 mm bolts securing the elbow.
Clean the mounting surface on the engine block.

Install the copper block-off plate between the engine block and the elbow.
After installation, warm up the engine and re-torque the bolts securing the copper plate.
(Refer to the illustration below.)

Step 9

Locate the EGR cooler coolant pipe running from the water pump, positioned below the front of the turbocharger.
Remove one (1) 10 mm bolt and one (1) 13 mm bolt, then remove the pipe.
(Refer to the illustration below.)

Step 10

Install the freeze plug into the removed pipe.
Using a flat surface tool wide enough to cover the inner face of the freeze plug, carefully tap the plug into place until fully seated.

Reinstall the coolant pipe.
(Refer to the illustration below.)

Step 11

Reinstall the intake pipe and all components that were removed for access.

Step 12

Start and warm up the engine, then re-torque all bolts securing the copper block-off plates to ensure a proper seal.