1. Introduction: The key role of the intake system in the 6.7L Cummins diesel engine
The intake system plays a pivotal role in maximizing diesel engine performance. In heavy-duty trucks like the Dodge Ram 2500 and 3500 equipped with the 6.7L Cummins engine, enhancing the intake system boosts horsepower, torque, fuel efficiency, and throttle response.
Factory intake systems prioritize emissions compliance and cost efficiency, often limiting airflow and engine output under heavy loads. Upgrading to a performance intake system like SPELAB's significantly improves airflow and reduces intake temperatures, leading to better combustion and higher overall power.
Moreover, a refined intake system minimizes turbo lag, crucial when towing heavy loads or off-roading. By optimizing airflow pathways and using premium materials, the SPELAB intake system upgrade kit unlocks the true performance potential of the 6.7 Cummins engine.
2. 6.7 Cummins Engine Intake System Differences Across Model Years
While the 6.7L Cummins engine has consistently delivered outstanding performance in the heavy-duty truck market since its debut in 2007, there are notable differences in intake system design across model years.
2007.5-2012 Dodge Ram 2500 and 3500 models featuring the 6.7 Cummins engine utilized a more conservative intake layout, which restricted airflow and led to higher intake air temperatures.
Moving into the 2013-2018 range, the 6.7L Cummins engine saw improvements to the intake manifold — commonly referred to as the 6.7 Cummins intake horn — offering better airflow but still suffering from excessive bends in the airflow pathway, limiting high-RPM performance.
For 2019 and newer models, while the overall intake system has been reinforced, OEM designs still made compromises to meet stringent emissions regulations. These compromises, particularly in the EGR system, heating elements, and heat shielding, prevent the engine from reaching its full potential.
Recognizing these differences, SPELAB has developed specially tailored intake system upgrade kits for each generation of the 6.7 Cummins engine. These upgrades feature more efficient airflow paths and an optimized 6.7 Cummins intake horn design, ensuring that both early and late model owners can unlock the full power of their engines.
3. The SPELAB Intake System Kit: A Full Performance Upgrade for the 6.7 Cummins Engine
The SPELAB intake system upgrade kit offers a complete performance upgrade for the 6.7 Cummins engine. Comparing OEM factory components to SPELAB's upgraded parts reveals significant advantages in performance, airflow, material craftsmanship, and design philosophy.
3.1 OEM Parts vs. SPELAB Upgrades — Performance Comparison
OEM intake systems typically compromise airflow efficiency and throttle response to meet emissions and cost requirements. By optimizing the hot and cold side intercooler pipes, upgrading to a high-efficiency intercooler, and eliminating the EGR throttle valve, the SPELAB intake system upgrade kit delivers an overall gain of about 50-70 horsepower. This improvement is particularly noticeable in models like the 2016 Dodge Ram 2500 with the 6.7 Cummins engine, enhancing towing and acceleration capabilities dramatically.
| Item | OEM Intercooler Pipes | SPELAB Upgraded Intercooler Pipes |
|---|---|---|
| Material | Plastic or mild steel | T6061 aerospace-grade aluminum with TIG welding |
| Inner Diameter | 2.75 inches (~70mm) | 3.5 inches (~89mm) |
| Airflow (CFM) | Approx. 450 CFM | Approx. 600-650 CFM |
| Pressure Drop | 12%-15% | Less than 5% |
| Heat Resistance | Up to 190°F (88°C) | Up to 350°F (176°C) |
| Weight | Heavier | Lighter with faster heat dissipation |
3.2 OEM Parts vs. SPELAB Upgrades — Airflow and Pressure Performance
Factory pipes and intake horns create significant airflow bottlenecks, especially at high RPMs, leading to insufficient air supply. SPELAB's large-diameter aluminum intercooler pipes and streamlined 6.7 Cummins intake horn design increase intake airflow by approximately 18%-25% while reducing pressure drop by over 15%. Whether it's a 2012 or a 2019 model 6.7 Cummins engine, drivers experience a fuller, smoother air delivery under full throttle.
| Item | OEM Intercooler | SPELAB High-Efficiency Intercooler |
|---|---|---|
| Core Density | Standard OEM design | +30% increased cooling surface |
| Airflow (CFM) | Approx. 600-700 CFM | Approx. 850-950 CFM |
| Intake Air Temp Drop | 30-40°F reduction | 50-60°F reduction |
| Material | Aluminum with average welding | Fully welded high-quality aluminum |
| Design Feature | Single flow path, prone to heat soak | Multi-flow high-efficiency cooling design |
3.3 Material Craftsmanship Comparison: Durability and Reliability
OEM components often use plastic or basic steel, prone to aging, cracking, or rust over time. SPELAB upgrades use high-strength T6061 aerospace-grade aluminum and precision TIG welding, offering superior heat resistance, corrosion protection, and minimal deformation under extreme loads. Whether towing in summer heat or operating in winter cold, models like the 2020 Dodge Ram 3500 with the 6.7 Cummins engine demonstrate outstanding stability and reliability.
| Item | OEM Intake Horn | SPELAB 6.7 Cummins Intake Horn |
|---|---|---|
| Material | Cast aluminum, untreated surface | CNC-machined aluminum with polished interior |
| Airflow Path Design | Multiple bends, airflow dead zones | Straight-through design, minimal resistance |
| Airflow (CFM) | Approx. 480 CFM | Approx. 620-650 CFM |
| Pressure Drop | Moderate, significant under load | Extremely low pressure drop |
| Throttle Response | Slight lag | Much faster and responsive |
3.4 Design Optimization: Fluid Dynamics and Thermal Management Innovations
When redesigning the 6.7 Cummins intake horn, SPELAB utilized CFD (Computational Fluid Dynamics) simulations to minimize dead zones and vortex areas, while eliminating unnecessary heat shields and heating elements to reduce heat soak. The upgraded intercooler core features a higher density arrangement, improving cooling efficiency by more than 30%, significantly lowering intake air temperatures, and enhancing combustion efficiency and power output.
| Item | OEM Heat Shield / Heater Components | SPELAB Heat Shield Delete & Heater Bolt |
|---|---|---|
| Structural Complexity | Additional parts occupying airflow space | Streamlined design, no obstruction |
| Thermal Management | High heat soak, hotter intake air | Reduced heat soak, cooler intake temperatures |
| Failure Rate | High (aging, loosening common) | Low (durable metal replacements) |
| Emissions Compliance | Meets factory emissions standards | Requires review of local emissions regulations |
3.5 System Synergy
Upgrading individual parts provides limited gains, but only by optimizing the entire intake system can full coordination between airflow, temperature, and pressure be achieved. The SPELAB intake system upgrade kit ensures that every component contributes to unlocking the complete performance potential of the 6.7 Cummins engine, offering a true full-system upgrade experience.
| Item | OEM EGR Throttle Valve | SPELAB EGR Throttle Valve Delete |
|---|---|---|
| Main Function | Controls partial exhaust gas recirculation, assists in cold starts | Fully removes EGR throttle for direct airflow |
| Material | Plastic valve body + electronic control | One-piece CNC aluminum construction |
| Airflow Restriction | Moderate (partially closes under load) | None (straight airflow) |
| Reliability | High failure rate, common codes (e.g., P0401) | No moving parts, extremely durable |
| Airflow Improvement | Airflow reduced by 5%-10% | Airflow increased by 10%-15% |
| Installation Difficulty | Requires maintenance/replacement over time | Easy bolt-on, permanent fix |
| Emissions Impact | Meets factory standards | May affect emissions compliance in some areas |
4. Why Choosing the Complete SPELAB 6.7 Cummins Intake System Upgrade Kit is the Smart Move
When upgrading the 6.7 Cummins engine, opting for a complete intake system—like the SPELAB intake system upgrade kit—rather than upgrading individual components is crucial for achieving maximum performance gains.
Each part of the intake system—including the 6.7 Cummins intake horn, intercooler, hot and cold side pipes, EGR throttle valve delete, grid heater delete, and heater bolt—works in synergy. Replacing just one piece may yield partial improvements, but OEM bottlenecks elsewhere will continue to restrict the engine’s full potential.
Take, for example, a 2015 Ram 2500 equipped with the 6.7 Cummins engine. Upgrading only the intake manifold might slightly improve airflow, but if the cold side intercooler pipe remains stock, with its smaller diameter and restricted flow, the overall system will still be limited. By installing the full SPELAB intake system upgrade kit, all airflow pathways are optimized, pressure losses minimized, and intake air temperatures lowered, resulting in an impressive 50-70 HP increase.
Furthermore, the complete kit ensures material consistency—using aerospace-grade T6061 aluminum—and uniform craftsmanship standards like precision TIG welding. This guarantees that each component will perform reliably under extreme conditions. On a 2020 Ram 3500 with a 6.7 Cummins engine, full system upgrades deliver superior towing performance, faster throttle response, and lower Exhaust Gas Temperatures (EGT), significantly reducing turbo lag.
Choosing the complete SPELAB intake system upgrade kit not only maximizes performance but also eliminates compatibility risks associated with mixing and matching different aftermarket brands. It ensures that your 6.7 Cummins engine operates at its absolute best, every time you hit the road.
5. Why Upgrading the Exhaust System Along with the Intake is Critical for Maximum Performance
While upgrading the intake system significantly boosts the 6.7 Cummins engine’s performance, pairing it with a high-flow exhaust system unlocks even greater gains.
OEM exhaust systems, designed for emissions and noise control, often restrict exhaust flow and increase backpressure. Even after installing a high-flow 6.7 Cummins intake horn, a stock exhaust can bottleneck the engine, slowing turbo response and limiting power output.
Real-world testing shows that synchronized intake and exhaust upgrades deliver an extra 15–25 horsepower, with smoother torque curves and quicker throttle response. On trucks like the 2020 Ram 2500, these upgrades also lower Exhaust Gas Temperatures (EGT) by 40–60°F, promoting engine longevity under heavy load
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For those seeking to fully unleash their 6.7 Cummins engine’s potential, upgrading both intake and exhaust systems is essential—not just for power, but for long-term reliability and efficiency.
6. Conclusion: Unleash the Full Power of Your 6.7 Cummins Engine — Share Your Build With Us!
Upgrading to the SPELAB intake system upgrade kit allows the 6.7 Cummins engine to fully unleash its potential, delivering up to 50-100 more horsepower while significantly improving throttle response, torque delivery, exhaust temperatures, and fuel economy. Whether for daily driving, heavy towing, or off-road adventures, SPELAB’s complete system upgrade brings a whole new level of performance to your Ram 2500 or 3500.
Already made the upgrade? Share your experience! Still considering? Drop us a comment with your questions or goals — let's push the limits of the 6.7 Cummins engine together!
7. FAQ
Q1: How much does a complete SPELAB intake system upgrade kit cost? How much can I save compared to buying components individually?
A1: The full kit typically costs between $1200 and $1500. Compared to purchasing individual components separately, you can save around $200-$300 while ensuring optimal compatibility and system performance.
Q2: How long does it take to install the complete SPELAB intake system upgrade kit? Is it difficult to install?
A2: Professional installation usually takes 4-6 hours. Experienced DIYers can expect to complete the job in 6-8 hours with basic mechanical skills. SPELAB provides detailed instructions to help simplify the process.
Q3: What common challenges might occur during installation?
A3: Potential challenges include removing rusted OEM parts, limited working space around the engine bay, and the need for precise pipe alignment. It's recommended to prepare a full set of tools and use penetrating lubricants during disassembly.
Q4: Is installing the SPELAB intake system upgrade kit legal? Will it affect emissions testing?
A4: While SPELAB systems are designed for performance enhancement, compliance with local regulations like CARB certification is necessary in some states (e.g., California). Always check local laws before installation.
Q5: Do I need to tune my ECU after installing the SPELAB intake system upgrade kit?
A5: Although the kit is designed for plug-and-play use, ECU tuning is recommended to optimize fuel delivery and ignition timing, allowing you to fully realize the system’s performance gains.
Q6: What kind of warranty and customer support does SPELAB offer?
A6: SPELAB provides a 12-month limited warranty covering manufacturing defects for the intake system upgrade kit. Customers can access support services through the SPELAB website or customer service hotline.
