3 ways to eliminate the Cummins ISB 6.7L killer problem: the heater bolt falling
Do you have a Dodge RAM equipped with a Cummins ISB 6.7L engine, model 2007.5 or newer? Then, this article is for you!
Today, we’re going to talk about a small component that can cause big problems: the connection bolt of your intake heater.
This bolt, affected by heat, thin out and weakens… With vibration, it detaches and falls into the engine.
In the Cummins ISB 6.7L engines, the intake heater is controlled by a solenoid that can sometimes stick.
If this happens, the system can overheat and damage the screw that holds the 12-volt supply tabs to the intake heater (also called the grid heater or the “toaster”).
With heat, this screw thin out, weakens, and, under the effect of vibrations, it eventually detaches and falls with the bolt into the intake manifold, making its way to cylinder #6. Once in the engine, the screw and nut can lodge in the head, in a piston, or make their way into the turbo, leading to major problems.
Is your intake screw showing signs of weakness?
To avoid this, the only solution is to regularly check that the bolt is still in place.
How? By removing your air intake and inspecting the power block to see if there is any abnormal play (the famous “wiggle test”).
If you notice any movement, it is crucial to address it as soon as possible.
Solutions to eliminate the Cummins ISB 6.7L killer problem
Fortunately, there are several ways to completely get rid of this risk. The solutions I’m going to propose depend on the year of your truck and whether your emission control system is modified or not.
Depending on the solution you choose, you might need to change or modify one or more of these parts: the intake plate, the grid heater, the intake elbow/EGR valve, and the air intake valve.
All options allow for the removal of the intake heater (the toaster). In addition to creating a risk with the bolt that holds it in place, it accumulates up with soot and carbon, which blocks the air going to your engine. Therefore, by changing your system, you will also improve the performance of your truck.
From left to right: The intake plate with the intake heater, the intake elbow with the EGR valve, and the air intake valve.
1. Universal option: The Banks Monster intake elbow
In addition to eliminating the possibility of engine breakage caused by the intake bolt falling, by allowing the removal of the element in the intake plate, the Banks system optimizes pressure and air distribution to the engine.
This system can be installed on all models of RAM 2500, 3500, 4500, or 5500 equipped with a Cummins ISB 6.7L engine, whether they are “deleted” or not.
If the truck is deleted, it is also possible to replace the air intake valve with a billet tube that will contribute to better airflow while giving a cool look to your setup.
2. Powerful option: Install an X-Flow intake elbow and intake heater element.
This system is composed of 2 elements: the intake elbow assembly and the BD X-Flow air heater. Once installed, it cancels the holes of the EGR valve and the air intake valve, thus allowing the removal of the toaster and eliminating the risk posed by the bolt. The combination of the 2 items is necessary for the truck to start correctly when it is cold.
The X-Flow kit can only be installed on Dodge RAM 2500 and 3500 produced between 2007.5-2018 whose emission control system has been modified, “deleted.”
3. Economic option: Install a Mega-Flo intake heater.
This device replaces the air intake valve and allows the removal of the toaster in the intake plate, thus preventing the risks of damage caused by the bolt falling.
The Mega-Flo can be installed on RAMs produced between 2007.5 and 2018 that have been “deleted” (i.e., whose emission control system has been modified).
To learn more: Mega-Flo Intake Heater Cummins ISB 6.7L 2007.5-20018
In summary, it is crucial not to underestimate the importance of the small intake bolt.
With the 3 solutions we have proposed, you can effectively eliminate the Cummins ISB 6.7L killer problem and ensure the reliability of your Dodge RAM.
At SML Diesel Performance, we are always here to support and advise you.