Performing an EGR delete on your 6.7L Powerstroke involves removing the factory Exhaust Gas Recirculation system,
enhancing performance and addressing potential reliability concerns. Numerous kits are available,
like those from Flashark and TM AG Tuning, offering complete solutions for a seamless installation process.
These kits, often including billet aluminum and stainless steel components, completely replace the EGR system,
requiring no additional parts for a full and effective modification.
Detailed instructions, such as those provided by SPEtuner, guide owners through each step.
The Diesel Dudes also offer comprehensive delete kits, simplifying the process for improved engine operation and longevity.
Understanding the EGR System and its Issues
The Exhaust Gas Recirculation (EGR) system on the Ford 6.7L Powerstroke is designed to reduce nitrogen oxide (NOx) emissions by recirculating a portion of exhaust gas back into the intake manifold. While effective for emissions control, this system introduces several potential issues for diesel engines.
Carbon buildup within the EGR cooler and intake manifold is a common problem, restricting airflow and leading to reduced engine performance. This accumulation stems from the soot inherent in diesel exhaust. Over time, this buildup can cause rough idling, decreased fuel economy, and even engine stalling.
Furthermore, the EGR cooler itself is prone to failure due to thermal stress and corrosion from exhaust gases. Leaks in the EGR cooler can result in coolant entering the intake, potentially causing catastrophic engine damage. Addressing these issues often requires frequent cleaning or replacement of EGR components, making an EGR delete a popular modification for Powerstroke owners seeking improved reliability and performance.
Benefits of Performing an EGR Delete
Implementing an EGR delete on a Ford 6.7L Powerstroke yields several performance and reliability advantages. Removing the EGR system eliminates the potential for carbon buildup within the intake manifold and EGR cooler, restoring optimal airflow and boosting horsepower and torque.
Reduced risk of EGR cooler failure is a significant benefit, preventing coolant leaks into the engine and avoiding costly repairs. Improved fuel economy is often observed as the engine operates more efficiently without the restriction of exhaust gas recirculation.
Additionally, an EGR delete can lead to quicker turbo spool-up times and a more responsive throttle. However, it’s crucial to pair the delete with appropriate ECU tuning to optimize performance and prevent error codes. Kits from companies like Flashark and SPETUNER are designed to maximize these benefits, offering a complete and effective solution.
Tools and Parts Required for the EGR Delete
Essential tools include sockets, wrenches, coolant drain pan, and potentially an exhaust pipe cutter. A complete EGR delete kit, like those from TM AG Tuning,
is crucial for a successful installation.
Essential Tools List
Successfully completing a Ford 6.7L Powerstroke EGR delete demands a specific set of tools for efficient and accurate work. A comprehensive socket set, encompassing both metric and standard sizes, is paramount, alongside a range of open-end and box-end wrenches. Torque wrenches are vital for ensuring proper fastener tightening, preventing leaks and damage.
Beyond these basics, a coolant drain pan is essential for safely collecting and disposing of the engine coolant. Pliers, including both standard and needle-nose varieties, will aid in disconnecting hoses and clamps. An exhaust pipe cutter might be necessary depending on the kit and exhaust modifications.
Additionally, consider having a set of screwdrivers (Phillips and flathead), a ratchet with various extensions, and potentially an OBDII scanner for post-installation diagnostics. Safety glasses and gloves are non-negotiable for personal protection throughout the process.
Comprehensive EGR Delete Kit Components
A complete EGR delete kit for the 6.7L Powerstroke typically includes several key components. Central to most kits is a robust exhaust cover plate, often CNC-machined from billet aluminum, designed to seal the exhaust manifold where the EGR tube once connected. Many plates, like those from TM AG Tuning, are tapped for the factory EGT probe.
Furthermore, kits generally feature stainless steel tubing to bypass the EGR cooler, ensuring a complete removal of the system. Coolant bypass components are crucial for maintaining proper engine temperature regulation after the EGR system’s removal.
Gaskets and necessary hardware, such as bolts and clamps, are also included to facilitate a secure and leak-free installation. Some kits, like those from The Diesel Dudes, may also incorporate an up-pipe for a more comprehensive delete.
Additional Supplies (Coolant, Gaskets, etc.)
Beyond the core EGR delete kit, several additional supplies are essential for a successful installation. A significant amount of fresh coolant is required, as the system must be drained and refilled during the process, particularly when implementing a coolant bypass. High-quality coolant compatible with your Powerstroke engine is crucial.
New gaskets are vital for ensuring leak-proof connections. These include exhaust manifold gaskets, coolant flange gaskets, and potentially up-pipe gaskets, depending on the kit and installation approach;
Thread sealant is recommended for certain fittings to prevent exhaust or coolant leaks. Penetrating oil will aid in loosening stubborn bolts. Finally, having extra shop towels and cleaning supplies on hand will help maintain a clean workspace throughout the installation.
Step-by-Step Installation Guide
The installation process begins with draining the coolant, followed by removing the factory air intake and then disconnecting the EGR system components.
Subsequently, install the new EGR delete kit, and finally, reconnect the coolant system.
Step 1: Draining the Coolant System
Before commencing the EGR delete, thoroughly draining the coolant system is paramount to prevent spills and ensure a clean working environment. Locate the drain cock, typically positioned at the lower radiator hose or engine block, and carefully open it to initiate the draining process.
Collect the coolant in a suitable container for responsible disposal, as it is environmentally hazardous. Allow sufficient time for complete drainage, potentially requiring removal of the radiator cap to facilitate airflow.
Once drained, inspect the system for any leaks or damage to hoses and connections. This initial step is crucial, as the EGR delete involves coolant bypass procedures, demanding a dry and intact system for proper execution. Remember to properly dispose of the used coolant according to local regulations.
Step 2: Removing the Factory Air Intake System
To facilitate access to the EGR system, the factory air intake must be completely removed. Begin by disconnecting the mass air flow (MAF) sensor and any associated wiring harnesses. Loosen the clamps securing the intake tube to the turbocharger and air filter housing.
Carefully detach the intake tube, ensuring no debris enters the turbocharger inlet. Remove the air filter housing and any connected ductwork. This process creates ample working space for subsequent EGR component removal.
Inspect the intake system components for any signs of damage or wear, considering potential upgrades during reassembly. Proper labeling of disconnected parts will aid in a smooth reinstallation process following the EGR delete completion. Ensure all sensors are protected during this phase.
Step 3: Disconnecting and Removing the EGR System
With the air intake removed, begin disconnecting the EGR system components. Start by carefully disconnecting the coolant lines connected to the EGR cooler, anticipating coolant spillage – have drain pans ready. Disconnect the electrical connector to the EGR valve.
Next, loosen and remove the bolts securing the EGR valve to the exhaust manifold. Detach the EGR tube from both the exhaust manifold and the intake manifold. Be cautious as some bolts may be corroded and require penetrating oil.
Once all connections are severed, carefully remove the entire EGR assembly, including the cooler and valve. Inspect the exhaust manifold for any cracks or damage during removal. Prepare the mounting surfaces for the EGR delete kit installation.
Step 4: Installing the EGR Delete Kit
Now, install the SPETUNER EGR Delete Kit, or a comparable kit from Flashark or TM AG Tuning. Begin by installing the exhaust cover plate, ensuring it’s properly aligned and secured with the provided hardware. Torque the bolts to the manufacturer’s specifications.
Next, install any up-pipes included in the kit, designed to bypass the EGR cooler feed inlet. Ensure a tight seal to prevent exhaust leaks. If your kit includes a coolant bypass, install it now, following the kit’s specific instructions for routing and securing the bypass lines.
Double-check all connections and ensure all components are firmly in place before proceeding to the coolant system reconnection and testing phases. A secure installation is crucial for optimal performance.
Step 5: Coolant System Reconnection and Bypass
After installing the EGR delete kit, reconnect the coolant system, or implement the provided coolant bypass. Many kits, like those from TM AG Tuning, include components to complete the coolant circuit, preventing leaks and maintaining proper engine temperature regulation.
Carefully route the coolant hoses, ensuring they are securely clamped to prevent any drips or pressure loss. If a bypass is utilized, follow the kit’s instructions meticulously to ensure proper flow and avoid overheating. Double-check all connections for tightness and proper alignment;
Once reconnected, slowly refill the coolant system, bleeding any air pockets to guarantee efficient cooling. This step is vital for preventing engine damage and ensuring long-term reliability.
Post-Installation Procedures
Following the EGR delete, ECU tuning and programming are crucial for optimal performance and to eliminate potential error codes. Thoroughly test for leaks
and verify proper functionality.
ECU Tuning and Programming
After completing the physical EGR delete, reprogramming the vehicle’s Engine Control Unit (ECU) is absolutely essential. Simply removing the EGR system will inevitably trigger a cascade of diagnostic trouble codes (DTCs), preventing the engine from running correctly and potentially causing performance issues.
ECU tuning effectively disables the EGR function within the vehicle’s software, eliminating these error codes and allowing the engine to operate optimally without the deleted components. Several tuning options are available, ranging from custom tunes tailored to your specific modifications to pre-loaded tunes designed for EGR delete setups.
It’s vital to choose a reputable tuner experienced with 6.7L Powerstroke engines. Proper tuning can unlock additional horsepower and torque gains, improve fuel efficiency, and ensure long-term engine reliability. Failing to tune the ECU after an EGR delete can lead to reduced performance, increased emissions, and potential engine damage.
Testing for Leaks and Proper Function
Following the EGR delete installation and ECU tuning, a thorough inspection for leaks is paramount. Begin by carefully examining all connections within the exhaust system, particularly around the EGR delete kit’s mounting points and the exhaust up-pipe. Any exhaust leaks can significantly impact performance and potentially damage surrounding components.
Next, inspect the coolant system bypass, ensuring there are no drips or signs of coolant loss. A compromised coolant bypass can lead to overheating and engine damage. Start the engine and allow it to reach operating temperature, while visually and audibly checking for leaks.
Monitor engine performance, paying attention to any unusual noises, smoke, or changes in power delivery. Scan the ECU for any remaining diagnostic trouble codes (DTCs) to confirm the delete was successfully implemented and the ECU is functioning correctly. A smoke test can help pinpoint elusive exhaust leaks.
Potential Issues and Troubleshooting
Common installation problems include coolant leaks, exhaust leaks, and error codes post-delete. Addressing these requires careful inspection, tightening connections, and re-flashing the ECU.
Ensure proper kit fitment and follow instructions closely to avoid complications during the 6.7L Powerstroke EGR delete process.
Common Problems During Installation
During the 6.7L Powerstroke EGR delete installation, several issues can arise. A frequently reported problem is difficulty accessing certain bolts due to their location, requiring specialized tools or extensions.
Another common challenge involves properly sealing the exhaust up-pipe to the new delete pipe, potentially leading to exhaust leaks if not fitted correctly. Coolant line disconnection and reconnection can also be tricky, increasing the risk of spills or improper sealing.
Some installers encounter issues with the EGR cooler feed inlet, needing the correct blocking method – either a disc or an up-pipe – to prevent exhaust backflow. Furthermore, stripped bolt heads or broken studs can occur, necessitating careful extraction techniques. Always double-check connections and torque specifications to mitigate these problems.
Addressing Error Codes After the Delete
Following a 6.7L Powerstroke EGR delete, the vehicle’s ECU will inevitably generate error codes due to the removed components. These codes typically relate to EGR system functionality and can illuminate the check engine light.
The primary solution is ECU tuning and programming. A custom tune disables the EGR system within the ECU, eliminating the error codes and optimizing engine performance for the modified setup. Several tuning options are available, tailored to different performance goals.
Without proper tuning, the truck may enter a reduced power mode or fail emissions testing. Ensure the tune is specifically designed for a deleted EGR system. Some kits may include a simulator, but a full tune is generally more effective and reliable in resolving these post-delete issues.
Legal Considerations and Emissions Compliance
Performing an EGR delete on your Ford 6.7L Powerstroke carries significant legal implications. It’s crucial to understand that removing factory emissions equipment, like the EGR system, is illegal in many jurisdictions, particularly if the vehicle is used on public roads.
Federal and state laws mandate emissions compliance, and tampering with these systems can result in hefty fines, failed vehicle inspections, and even legal prosecution. The legality varies greatly depending on your location and vehicle usage.
EGR deletes are often permissible for off-road use only. Before proceeding, thoroughly research your local emissions regulations. Consider the potential consequences and ensure you are fully aware of the legal ramifications before modifying your vehicle’s emissions control systems.