EGR & DPF Delete Horsepower Gains: What Really Happens

Your diesel truck feels sluggish. Regen cycles interrupt your drive. You wonder if deletes can fix it and add real power.

A common question asked by owners of diesel vehicles is, "Does EGR delete/DPF delete increase horsepower?" The EGR (Exhaust Gas Recirculation) and DPF (Diesel Particulate Filter) deletes involve removing the emissions control devices.

Yes, removing EGR and DPF with proper tuning increases horsepower by 30-80 HP and torque by 100-180 lb-ft on most modern diesels, while improving throttle response and fuel economy.

Does EGR delete increase horsepower when combined with DPF removal? Explore performance gains, tuning benefits, fuel economy changes, and legal risks below.

I have tuned many trucks over the years. One of my own 6.7L Cummins felt restricted stock. After a careful delete and tune, it woke up. But gains come with risks. Keep reading and make informed decisions before modifying your diesel trucks.

How EGR and DPF Systems Restrict Engine Performance

EGRs and DPFs were built for emission control, but they put extra load on the engine, which makes it difficult to breathe and perform well.

This added load restricts airflow to the engine and reduces fuel combustion in the engine itself, resulting in decreased engine performance. Many owners feel frustrated with slow spool and lost efficiency.

EGR and DPF restrict flow, reduce efficiency, and build backpressure, costing you horsepower, torque, and fuel economy in daily driving.

Now let's break down each system. I will explain how they work and why they hold back performance.

What the EGR System Does and How It Impacts Power

The EGR (Exhaust Gas Recirculation) system is comprised of an exhaust pipe that allows a part of the exhaust to be directed back into the intake.

It lowers Nitrogen Oxides (NOx) emissions produced by internal combustion engines. However, it also causes reduced efficiency in the combustion process because the exhaust gases are replacing some of the fresh oxygen needed for optimal fuel burning.

Because of these effects, you notice a more gradual compressor boosting due to slower spooling and a slower throttle response, and increased soot buildup in the intake and combustion chambers.

Ultimately, this results in lower power output and reduced performance, particularly when towing or when experiencing extreme torque loads.

I saw this on a friend's Powerstroke. It had soot buildup everywhere. Throttle felt lazy.

What the DPF Does and Why It Creates Exhaust Restriction

DPF traps particulate matter from diesel exhaust gases to reduce air pollution. Although this is a positive function for the environment, DPFs generate back-pressure on the engine that restricts airflow.

This back-pressure limits engine horsepower and torque, and may also cause turbocharger lag, due to less airflow reaching the turbo. The engine has reduced horsepower during DPF regeneration cycles (when the DPF allows the burning off of accumulated soot).

They use extra fuel. EGTs spike. They rob 50+ HP on many trucks.

When diesel engines have clogged or become heavily loaded with soot again, they tend to have lower acceleration and efficiency, which results in the vehicle being perceived by the operator as being less responsive.

Delete kits free the power. But only with tuning.

Does Removing EGR and DPF Increase Horsepower?

You see claims everywhere. Some say huge gains. Others say minimal. What is real?

Yes. DPF and EGR deletes increase power, but the gains vary significantly. Off-road builds with proper tuning typically see 30-70 HP gains and 100-180 lb-ft torque increases.

While the EGR and DPF are removed to increase the power of an engine, the degree to which this occurs depends on how your vehicle was set up through tuning and what type of engine build you have.

Less exhaust backpressure and better airflow mean that the engine can produce more torque and horsepower, but each diesel platform will have different gains based on its configuration and tuning.

Most importantly, without using proper tuning, these gains will not be fully realized, and you may have issues with drivability or excessively high EGTs (exhaust gas temperatures).

I tested several trucks on dynos. Results match forums and shops. Gains come from better flow and tuning.

Combined EGR + DPF Delete Power Gains

Most owners do both. It unlocks the most. Tuning adds fuel and boost safely. Lower EGTs help.

Off-road builds with proper tuning typically see 30–70 HP gains and 100–180 lb-ft torque increases. Break this down by popular diesel platforms.

Popular Diesel Platform Gains

Platform	Stock HP	After Delete + Tune	Gain
6.7L Power Stroke (2011-2019)	~390–400 HP	440–470 HP	+50-100 HP
6.7L Cummins (2007.5-2018)	~350-385 HP	420-500 HP	+70-115 HP
6.6L Duramax L5P (2017-2024)	445 HP	500-600 HP	+55-155 HP

These numbers reflect real-world dyno-tested results from enthusiasts and professional shops. Numbers vary by tune level and mods.

Conservative tunes give smaller, safer gains. Aggressive ones push higher. My Cummins went from 350 HP stock to 460 HP deleted and tuned. Torque jumped 150 lb-ft. It tows better now.

What's the Real HP Difference Between DPF and EGR Deletes?

Owners ask which gives more. Is one enough? Let's look at real data.

DPF delete adds more direct HP from reduced backpressure. EGR delete improves response and longevity. Combined gives the best results.

I ran tests. DPF alone gave a quick spool. EGR alone cleaned the intake.

Each system affects horsepower differently; therefore, performance gains will also differ. To determine which delete is the most beneficial for achieving their goals, it is important to understand the actual impact of removing each of the EGR and DPF systems from an engine.

Real-World Horsepower Gains After EGR Delete

Typically, removing the EGR from your vehicle can increase horsepower between 20 – 50 HP, depending on the type of engine and tune.

Generally, the horsepower increase will be accompanied by an increase in throttle response and reduced throttle lag. Turbo spools faster without hot gases.

In addition, lower EGTs allow safer aggressive tuning later. Soot stops building. Intake stays clean longer.

I did EGR only on one truck first. Response improved a lot. Peak power rose slightly on the dyno.

Real-World Horsepower Gains After DPF Delete

Compared to EGR removal, DPF deletion typically generates a greater amount of power gain due to reduced exhaust backpressure from the DPF.

Numerous Dyno test results reflect that horsepower gains range from 30-80 with a noticeable increase in torque.

Backpressure drops big. Exhaust flows freely. The engine is now able to spool the turbo faster, giving the engine an improved level of acceleration as well as better performance when towing. Torque comes lower.

The removal of backpressure supports more consistent power delivery over longer periods of time when the engine is running under high-load conditions.

One Duramax gained 35 HP from the DPF pipe alone. Then, tuning added more.

Combined is king. Each fixes different restrictions.

Performance Benefits Beyond Increased Horsepower

Beyond horsepower gains, EGR deletes offer additional benefits.

Delete kits lower heat, save fuel, boost turbo life, and build reliability when done right.

EGR delete advantages include improved throttle response, reduced soot buildup, and more efficient combustion when properly tuned.

Many diesel truck owners experience improved engine performance after performing a delete. They often see increased efficiency as a result of the modification.

Overall, engine reliability can also improve when the engine is properly tuned to compensate for the deletion.

I notice these daily. My truck runs cooler towing.

1. Lower Exhaust Gas Temperature (EGT)

No EGR means cooler intake air. Combustion runs cleaner. EGTs drop 200-400°F. Safer for hard pulls.

When EGR and DPF are removed or deleted from the engine, the exhaust gas temperature will be much lower than that of a factory-equipped diesel truck.

With the elimination of EGR and the additional heat generated during regeneration, it is common for the diesel engine to operate at much lower EGTs while under maximum load.

Lower EGT is beneficial for component longevity. It reduces thermal stress on the turbocharger, pistons, and valves. This helps minimize the risk of long-term engine damage during towing or heavy-duty driving.

2. Improved Fuel Economy

No regens waste fuel. Less backpressure helps efficiency. Many see 2-5 MPG better. Depends on driving.

Diesel enthusiasts often ask, Does DPF delete increase MPG?

Removing the DPF allows the engine to breathe better and burn fuel more efficiently, which can result in highway gains of 1–3 MPG. The increased fuel efficiency from reduced backpressure and cleaner exhaust will allow the diesel engine to burn fuel more efficiently.

The amount of fuel saved varies based on each engine's particular tune and individual driving habits.

3. Improved Turbocharger Performance

Faster spool. Less lag. Turbo works easier. Longer life without soot.

When DPF is removed, there is an increase in air flow, therefore allowing quicker spooling time for the turbocharger. The removal of EGR keeps the intake free of soot, helping to improve airflow.

Together, these modifications improve boost response and reduce turbo lag, allowing for smoother power delivery across the RPM range.

4. Increased Engine Lifespan When Properly Tuned

Clean intake. No cooler failures. Less stress. Proper tuning prevents overfuel issues.

When properly tuned, EGR and DPF deletes can reduce internal wear and improve component longevity. Many truck owners ask, Does deleting a diesel make it last longer? The answer is yes, provided high-quality kits and tuning are used.

I have over 200k miles on deleted trucks. They run strong.

Cleaner intake air, lower EGTs, and reduced regeneration cycles equal reduced internal wear of the engine components. Proper tuning is essential. Because improper tuning could reverse the effects of both the EGR and DPF deletes and significantly shorten the life of the engine.

Required Supporting Mods: Tuning and Exhaust Changes

You can't just remove parts. Truck throws codes. It may limp.

EGR and DPF delete must have supporting modifications to function properly, increase power safely, and provide reliable drivability. Tuning is a must. Exhaust helps flow.

I learned the hard way early. Untuned delete caused problems.

Why a Tune Is Required for EGR/DPF Deletes

In order to achieve an effective functioning EGR and DPF delete, a corresponding engine tune must be performed after EGR and DPF deletion.

ECU expects sensors. Delete removes them. Tune turns off checks. Adjusts fuel and boost.

The engine control unit is recalibrated to allow for proper adjustment of the fuel maps, turbo control, and air-to-fuel ratios. Additionally, regeneration logic must be disabled to stop the engine from attempting to perform DPF burn cycles.

Without these changes, the engine cannot properly manage airflow or fueling, which limits power and creates reliability issues.

What Happens If You Delete Without Tuning

Check engine light on. Limp mode kicks in. Drivability suffers. The truck feels worse.

If you delete an EGR or DPF on a truck without first tuning the engine, there will be immediate issues associated with this removal. The check engine light will be illuminated, and the engine will likely go into limp-home mode.

Fuel delivery will be erratic, throttle response will be slow, and the overall drivability will suffer. In most cases, the vehicle will become very unsafe if driven, especially if loaded or towing something.

Delete Pipes, Downpipes, and Exhaust Options

A straight pipe is loud. Performance exhaust balances sound.

The primary purpose of delete pipes is to replace factory restrictive exhaust systems with less restrictive systems so the exhaust can flow more freely out the back of the engine.

Straight pipe systems have maximum airflow capability and will produce a very aggressive sound. Performance exhaust systems are designed to allow for maximum exhaust flow while providing more controlled sounds.

Both types of systems improve performance through reduced backpressure and quicker turbo spool from an engine producing power smoothly and consistently.

4-5 inch flows best. Impacts tone and flow.

I run a 5-inch with a muffler. Deep rumble without drone.

EGR DPF Delete Cost Breakdown

Costs add up quickly. Parts, tune, exhaust, labor.

Hardware ($1,800-$3,800), custom ECU/TCM tuning ($500-$1,200), turbo-back exhaust ($700-$1,500), and labor ($600-$1,500), totaling approximately $3,600-$8,000. Shop around. DIY saves labor.

The ultimate expenses of an EGR and DPF delete depend on the truck platform, accessory quality, and tuning method. Most complete delete setups can be estimated within a typical price range.

Hardware normally costs between $1,800-$3,800. Additional hardware includes EGR delete kits, DPF delete pipes, and block-off components.

Custom ECU or TCM tuning is also commonly available for an additional cost of $500-$1,200, depending on the experience of the tuner and the complexity of the vehicle.

A complete turbo-back exhaust system will typically add $700-$1,500, with labor costs varying between $600-$1,500.

Overall, most diesel truck owners will invest between $3,600-$8,000 for a complete EGR and DPF delete setup.

4" DPF Delete & EGR Cooler Delete Kit For 2011-2015 Duramax LML

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My full setup cost $5,000. Worth it for me.

The Legal Reality: Are EGR and DPF Deletes Allowed?

Delete kits are illegal for on-road use in the US. EPA enforces the Clean Air Act.

EGR and DPF deletes are heavily regulated in the United States. While these modifications can increase performance, they come with serious legal consequences.

1. Federal EPA Regulations (United States)

Per Federal EPA Regulations, it is illegal to remove or disable emissions control devices from any diesel-powered trucks operating on the road, including but not limited to EGR systems and DPFs.

Both vehicle owners and repair shops can face substantial fines. These penalties apply even if the truck passes a basic safety inspection.

2. State Inspection and Smog Test Consequences

The majority of states enforce emissions regulations using an OBD check and visual inspections. Most deleted trucks do not pass the emissions test because they either have missing components or have disabled readiness monitors.

In addition, some states have additional diesel emissions regulations that make it difficult or impossible to register deleted vehicles.

3. Warranty and Insurance Impact

Removing emissions components results in the voiding of the powertrain warranties on most vehicles. Manufacturers deny powertrain warranties for engine or turbo failure.

Insurance claims for deleted vehicles are generally denied if an accident occurs or if the deleted vehicle is subject to a compliance inspection.

Risks and Downsides of Removing EGR and DPF

Although deleting EGR and DPF components from diesel engines improves their performance, diesel owners should carefully evaluate the downsides.

More emissions. Louder. Smellier. Bad tune risks the engine.

One of the major issues is environmental impact. By removing these components, diesel engines produce greater amounts of NOx and particulate matter. This result leads to increased pollution in the air.

In addition, deleted diesel trucks produce stronger exhaust smells and increased noise when using straight exhaust pipes. The noise can make daily travel uncomfortable and unduly attract unnecessary attention.

One of the larger problem areas associated with deleted diesel trucks revolves around the quality of the tuning and delete kits. Poor-quality or low-quality delete and tuning products can lead to high EGTs or excessive smoke being emitted by the engine.

High EGTs can cause extreme heat and damage to certain components of the engine, including the turbochargers. Similarly, using low-quality EGR/DPF delete kits can lead to leaks in gaskets and seams due to system failure. This can result in poor engine performance and reliability issues.

FAQs

Do deletes improve turbo longevity?

Yes. By reducing backpressure and lowering EGTs, EGR and DPF deletes reduce stress on the turbocharger when paired with proper tuning.

How much horsepower does a DPF delete add?

A DPF delete typically adds 30–80 horsepower, depending on the engine platform and tuning quality.

How much horsepower does an EGR delete add?

An EGR delete usually adds 20–50 horsepower, with noticeable improvements in throttle response and drivability.

Can you gain power without deleting emissions?

Yes. Emissions-on tunes add 50-100 HP safe. Performance tuning, upgraded exhausts, and intake improvements can increase power. But gains are lower compared to full deletes.

Is it safe to drive a deleted diesel truck?

Yes, but only with proper tuning and maintenance. Poor tuning increases engine wear and reliability risks.

Are EGR/DPF deletes worth it purely for horsepower?

If off-road and tuned right, yes. For street, consider legal risks and fines, while power gains are real. The delete kits are best suited for off-road or competition builds.

Conclusion

Deletes unlock real power and reliability off-road. Gains impress. But legal risks are serious.

Removing EGR and DPF systems does increase horsepower and torque by improving airflow and reducing exhaust backpressure. Real-world data shows gains of 30–70 HP and 100–180 lb-ft of torque when deletes are paired with proper tuning.

Additional benefits include lower EGTs, better throttle response, and improved turbo performance.

For diesel owners asking, "Does EGR/DPF delete increase horsepower?", the answer is yes, especially when combined with proper tuning and supporting modifications.

However, these gains come with clear trade-offs. EGR and DPF deletes are illegal for on-road use in the United States, can void warranties, and may cause insurance issues.

For off-road or competition builds, deletes can deliver strong performance gains. For daily-driven trucks, legal alternatives may be the better choice.

I enjoy my deleted truck off-road. For the street, I recommend emissions-intact tuning. It balances performance and compliance.

About the Author- John Barrett

More Reading

• Diesel Particulate Filter
• Exhaust Gas Recirculation
• Diesel Particle Filter Emergency Regeneration