Install a Ford 6.7 EGR Delete Kit: 2011–2019+ Complete Guide

Clogged EGR coolers on 6.7 Powerstrokes choke airflow, spike EGTs, and kill reliability under load. This can lead to soot-packed coolers, overheating, and power loss. An off-road EGR delete kit restores flow and reliability.

Installing a 6.7 Powerstroke EGR delete requires draining coolant, removing the cooler and pipes, fitting block-off plates, rerouting coolant, and loading an off-road ECM tune to prevent DTCs like P0401 and limp mode.

Looking for Ford 6.7 EGR delete instructions to get started? This guide walks through the full EGR delete 6.7 Powerstroke process from start to finish. You will learn about tools, safety prep, coolant bypass, removing components, block-off plates, post-install leak checks, and required tuning.

Before you grab a wrench, know this clearly. EGR deletes are intended strictly for off-road or competition use. Removing emissions equipment on a street-driven truck violates federal and local emissions law.

Why Do 6.7 Powerstroke Owners Install an EGR Delete Kit?

Owners install EGR delete kits on 2011-2019+ 6.7 Powerstrokes to stop cooler clogging, reduce soot recirculation, lower EGTs, and restore airflow for better reliability under tow or competition use.

Cooler Clogging and Soot Buildup Mechanics

The 6.7 Powerstroke routes hot exhaust gas through a liquid-cooled EGR cooler before mixing it back into the intake. Soot and oil vapor stick to the cooler tubes.

Over 50,000-80,000 miles, the core restricts. Exhaust backpressure rises. EGTs climb 150-250°F under load. Coolant temperatures follow. The PCM pulls timing and fuel to protect the engine, cutting power.

Heavy towing or modified tunes accelerate the process. The small EGR valve and cooler passages never see full cleaning during normal regen cycles. Once restricted, the cooler becomes a heat source instead of a heat exchanger.

Overheating and Reliability Risks Under Load

Restricted flow forces the engine to work harder to push exhaust. Cylinder temperatures rise. Head gasket and injector longevity suffer.

We see trucks enter limp mode with codes P0401 (insufficient EGR flow) or P2457 (EGR cooler efficiency). The delete removes the cooler and pipes entirely, ending the restriction.

Recirculating hot soot back into the intake manifold is a major cause of sticky intake valves and rapid oil degradation on the Scorpion engine.

However, bypassing these emission components involves key trade-offs regarding street legality and vehicle inspection compliance. Read our full analysis on 6.7 Powerstroke EGR delete pros and cons to evaluate if this modification suits your truck.

Issue	Factory EGR System	After Off-Road Delete
Cooler restriction risk	High after 60k miles	Eliminated
Typical EGT rise under tow	+150-250F	Baseline restored
Common DTCs	P0401, P2457	Prevented by tune

What Important Things Must You Know Before Starting a 6.7 Powerstroke EGR Delete?

Before any 6.7 Powerstroke EGR delete, confirm off-road-only use, match the kit to the exact model year harness and bracket layout, and honestly judge your mechanical skill against the 6-10 hour job that includes coolant work and mandatory tuning.

Legal and Emissions Compliance Warnings

Tampering with emissions controls breaks federal Clean Air Act rules for on-road vehicles. Federal EPA rules ban EGR deletes on any vehicle used on public roads.

States with smog testing can fail your truck during inspection. You could also face fines from local authorities.

An EGR delete can void your factory powertrain warranty immediately. Insurance claims may also get denied if a modification caused damage. Resale value often drops too since many buyers want stock emissions setups.

Who should not do this: Daily drivers in California, New York, or any emissions-tested county should not perform this work. Leased trucks and vehicles still under factory warranty belong in the same category. Competition or pure off-road trucks remain the only legal use case.

Model Year Differences and Compatibility

Fitment differs across 2011 to 2014, 2015 to 2016 and 2017 to 2019+ trucks. Bracket locations shift. The three-plug cooler harness changes locking-tab style. Intake tube routing and degas tank clearance vary.

Before ordering the parts for your 6.7 Powerstroke EGR delete kit, always be sure to verify the instructions for your exact model year. Using a 2011-2014 plate set on a 2017 truck leaves gaps and leaks.

Harness length and sensor plug orientation also differ. The PCM connector near the firewall sits in slightly different spots across generations. Always verify the kit part number against the truck’s build date before opening the box.

DIY vs Professional Installation

A first-time installer with basic metric tools and a solid mechanical background can complete the job in 8-10 hours. Experience with coolant systems and torque specs shortens that to 5-7 hours.

If you uncomfortable draining coolant, working around hot-side fasteners, or loading ECM tunes, a shop install is safer. Snapped bolts and coolant leaks are common mistakes for first-timers.

Labor rates run $800-1,400 depending on location and whether the tune is included.

Factor	DIY Ready	Shop Recommended
Skill level	Comfortable with sockets, torque wrench, coolant work	Limited diesel experience
Time available	Full weekend	Need truck back same day
Tools on hand	Metric set, torque wrench, drain pan	Missing specialty tools
Tune access	Owns programmer or has trusted tuner	Needs full service package

What Tools and Parts Do You Need for a 6.7 Powerstroke EGR Delete?

A complete 6.7 Powerstroke EGR delete requires metric sockets from 8 mm to 13 mm, a 5 mm Allen key, torque wrench, coolant drain equipment, Motorcraft-spec coolant, the full delete kit with three block-off plates and reroute hose, plus safety glasses and gloves.

Basic Hand Tools and Hardware

• Metric sockets and wrenches (8mm, 10mm, 13mm)
• 5mm Allen keys and a torque wrench
• Extensions, universal joints and penetrating oil
• Zip ties for wire management

Coolant Equipment and Consumables

• Coolant drain pan, funnel and shop rags
• Thread sealant if your kit specifies it
• Motorcraft approved replacement coolant
• Motorcraft OEM-approved coolant

Delete Kit Components Verification

• Exhaust block-off plate and intake block-off plate
• Coolant block off plate and reroute hose
• Barbed fittings, hose clamps and mounting brackets
• New O rings, gaskets and sensor caps

Recommended Safety Gear

safety glasses, heavy duty gloves, nitrile gloves and proper vehicle support equipment are essential for this job.

Category	Required Items	Notes
Sockets & Wrenches	8 mm, 10 mm, 13 mm	Plus extensions and U-joints
Specialty	5 mm Allen, torque wrench	Follow kit torque specs exactly
Coolant	Drain pan, funnel, Motorcraft coolant	Never mix coolant chemistries
Kit	3 block-off plates, reroute hose, clamps, O-rings	Verify year-specific fitment

How Do You Prepare the Truck Safely Before an EGR Delete?

Safety prep for a 6.7 Powerstroke EGR delete means letting the engine cool completely, disconnecting both negative battery terminals, and draining the coolant system into a clean container before any component removal.

Let the Engine Cool Completely

Wait for engine to cool down before handling it. The hot, pressurized cooling system may cause serious injuries if it comes in contact with skin.

Disconnect Both Batteries

Disconnect both negative battery terminals next. This will help to prevent damage to the electrical system when disconnecting sensors and connectors from it.

Drain the Coolant System Safely

Find the radiator drain plugs on both sides of the truck. Drain the coolant into a clean container for disposal or reuse. Approximate loss: 10 to 15 quarts of coolant will be lost during this phase.

How Do You Install an EGR Delete Kit on a 6.7 Powerstroke Step by Step?

A 6.7 Powerstroke EGR delete installation follows nine clear stages: remove the air intake for access, disconnect sensors and vacuum lines, reroute coolant, unbolt and extract the EGR cooler and pipes, install the three block-off plates, reassemble the bay, refill and bleed coolant, flash an off-road ECM tune, then start the truck and verify no leaks or codes.

These 6.7 EGR delete instructions are valid for 2011-2019+ trucks with a few differences in brackets.

Step 1: Remove the Air Intake and Gain Access

Disconnect the Mass Air Flow sensor harness first. Release the intake hose clamps and remove the 8mm mounting bolts. Remove air filter box from rubber feet and put it aside.

Pull the remaining intake tubes free. Release coolant lines from their factory retaining clips. Remove any heat shields blocking access. Move the degas tank aside if needed for clearance.

Step 2: Electrical, Sensor and Vacuum Disconnections

Unplug the EGR temperature sensor and secure the harness away from heat. Disconnect the PCM harness connector near the firewall.

Find the three plug harness on top of the EGR cooler. It includes an orange or yellow locking tab, a grey plug and a black plug with a metal clip. Unplug each one carefully.

Cap the vacuum line on top of the EGR system using the supplied rubber cap. Disconnect the throttle valve connections near the fan shroud as needed.

Step 3: Disconnect and Reroute Coolant Lines

Locate the main coolant hoses feeding the EGR cooler, including the small T line connection. Release the clamps and pull these factory lines free.

Install the supplied straight barbed fitting and secure it with hose clamps. Confirm the bypass route matches your specific kit instructions exactly. This keeps coolant flowing continuously through the engine.

Step 4: Remove EGR Pipes and the Cooler Assembly

Remove the short EGR pipe, which uses 4 bolts. Then remove the long EGR pipe, which uses 5 bolts and a support bracket. Save the factory gaskets and hardware if reusable.

Unbolt the EGR cooler from the engine. There are usually 6 to 7 mounting bolts holding it in place. Remove the nut securing the hard pressure line at the firewall.

Twist and pull the cooler forward off its mounting dowels. Clear any remaining clips or wiring as you remove it.

Pro tip: Apply penetrating oil to hot side bolts a day before starting work. This reduces the chance of snapped fasteners on heat seized hardware. Controlled heat, along with penetrating oil can be used to help loosen stubborn or heat-seized bolts.

Step 5: Install the Block Off Plates

Clean all mating surfaces on the exhaust and intake manifolds thoroughly. A clean surface prevents leaks after reassembly.

Install the exhaust block off plate using factory hardware and a fresh gasket. Install the intake block off plate with the supplied O ring and Allen head bolts. Do not reuse the factory intake gasket here.

Secure the coolant block off plate with its supplied hardware. Torque every bolt to your kit's exact specification, usually around 18 to 28 ft lbs. Cap any remaining open vacuum ports, unused lines or sensor connectors.

Step 6: Reassemble the Engine Bay

Reinstall heat shields, brackets and the degas tank if you moved them earlier. Put the air filter housing and intake tubes back in place. Make sure that each hose clamp is properly tight.

Use zip ties to secure the unconnected EGR wires and vacuum lines to the PCM harness. Keep everything clear of moving parts and hot exhaust surfaces. Reconnect both battery cables once wiring is secured.

Step 7: Refill Coolant and Bleed the System

Refill the cooling system with Ford-spec coolant. Run the bleed procedure to clear air pockets from the engine block. Trapped air can cause overheating if skipped.

Check all hose connections, clamps and block off plates prior to turning the engine on. Small leaks caught early will minimize the big headache later.

Step 8: Tune the ECM

Custom tuning is mandatory after any EGR delete 6.7 Powerstroke install. The factory ECU expects EGR feedback data. Without it, the truck triggers limp mode almost instantly.

Untuned trucks commonly throw codes like P0401, P0402, P2457, P1249 and P0475. A delete capable tune stops the ECM from flagging these faults.

Choose a tuner for a 6.7 Powerstroke. Look for solid fueling and boost strategy plus good post-install support. Before heading the truck anywhere, flash the ECM with an off-road tune.

Step 9: Start the Truck and Perform Final Checks

Turn engine on and warm it up until it reaches operating temperature. Take special note of any coolant leaks, exhaust leaks or intake leaks during this period.

Confirm no check engine light or limp mode message appears on the dash. Let the truck cool down again, then check the degas tank coolant level. Top it off as needed.

Step	Key Action	Critical Detail
1	Intake removal	Unplug MAF first
2	Sensor disconnect	Cap vacuum line
3	Coolant reroute	Match kit hose path exactly
4	Cooler extraction	Save hardware, use penetrating oil
5	Block-off plates	Clean surfaces, torque to spec
6	Reassembly	Zip-tie harnesses clear of heat
7	Coolant refill	Bleed all air pockets
8	ECM tune	Mandatory before driving
9	Final checks	Monitor leaks and codes at temp

What Tips Make a 6.7 Powerstroke EGR Delete Installation Smoother?

Label every hose and connector, photograph the engine bay before disassembly, soak hot-side fasteners in penetrating oil the night before, follow the exact kit instructions, and double-check every quick-connect coolant fitting before the final start.

Small habits prevent lost parts, wrong connections, and broken bolts. Preparation separates a clean job from a frustrating one.

• Label every hose, plug and connector with tape before removal
• Take clear reference photos of the engine bay first
• Soak hot side fasteners in penetrating oil a day early
• Follow your specific kit manual exactly, not generic steps
• Double check every quick connect coolant fitting for a tight seal

Labeling and Photography

Tape labels on every disconnected hose, plug, and connector. High-resolution photos of the original layout give an instant reference when something does not look right during reassembly.

Penetrating Oil Timing

Apply penetrating oil to all exhaust-side and hot-side fasteners 24 hours ahead of time. The oil works deeper overnight and reduces the chance of snapped bolts.

Kit Instructions and Fitting Checks

Every kit differs slightly in hose length and plate design. Follow the printed steps for your exact part number. After installing the coolant bypass, tug every quick-connect fitting to confirm it is fully seated and locked.

How Long Does It Take to Install an EGR Delete Kit on a 6.7 Powerstroke?

A typical DIY 6.7 Powerstroke EGR delete takes 6-10 hours. First-time installers often need a full weekend; experienced mechanics finish in 5-7 hours. Seized bolts, missing tools, or coolant air pockets add the most time.

Estimated Time for DIY Installation

A first time DIY install typically takes 8 to 12 hours. This includes prep work, coolant draining and the full bleed process at the end.

What Can Slow the Job Down

Snapped bolts, tight brackets or coolant bleeding issues can slow the job further. Missing tools or an unclear 6.7 Powerstroke EGR delete kit instructions manual also adds delays.

First-Time Installer vs Experienced Mechanic

An experienced mechanic familiar with 6.7 Powerstroke EGR delete instructions can often finish in 6 to 8 hours. Shop diesel tech, who has performed multiple 6.7 Powerstroke deletes, finishes the mechanical work in under six hours and the tune in under thirty minutes.

Installer Level	Typical Time	Main Time Sink
First-time DIY	8-12 hours	Learning harness routing and bolt locations
Experienced DIY	6-8 hours	Seized hardware
Shop technician	4-6 hours	Customer wait time only

What Common Problems Occur During a 6.7 Powerstroke EGR Delete?

Common problems during a 6.7 Powerstroke EGR delete include snapped or seized bolts, coolant leaks at O-rings or clamps, Check Engine Lights from incomplete tunes, intake or boost leaks at block-off plates, and programmer connection failures during the flash.

• Snapped or seized bolts: Always use penetrating oil, use of gentle heat and quality extractors to remove broken bolts safely.
• Coolant leaks after reassembly: Re-seat O rings, re-check reroute line and confirm all clamps are properly torqued.
• Check engine light or fault codes: ensure harness connections are properly inserted, and retune your ECM if trouble codes remain. Check connector pin integrity during troubleshooting
• Intake or boost leaks: recheck block off plate alignment and confirm the mating surface was clean during install.
• Tune not loading correctly: check the programmer cable connection and confirm your software version matches your truck.

If your truck suffers from sluggish acceleration or throws boost pressure fault codes after reassembly, a loose intercooler boot or an exhaust leak at the bypass plate is often the culprit. For step-by-step diagnostic procedures on fixing boost leaks, refer to our troubleshooting walkthrough on P0299 6.7 PowerStroke errors.

How Do You Maintain a 6.7 Powerstroke After an EGR Delete?

Post-EGR-delete maintenance on a 6.7 Powerstroke centers on regular coolant level and condition checks under heavy loads, visual inspection of block-off plates and reroute hoses for seepage, and continued attention to DPF soot loading because an EGR delete alone does not remove the particulate filter.

Coolant Monitoring Under Load

Check the degas tank before and after every long tow. Low coolant after a hard pull often signals a slow seep at a clamp or plate. Test coolant condition every 15,000 miles and replace at the normal Ford interval.

Block-Off Plate and Hose Inspection

Every oil change, look at the exhaust and intake plates for soot trails or wet spots. Feel the reroute hose for soft spots or swelling. Replace any compromised clamp or hose immediately.

DPF and CCV Considerations

An EGR delete stops soot from recirculating into the intake, yet the DPF still traps particulate from the exhaust stream. Regen cycles continue. Diesel particulate filter soot loading is still an issue that needs attention.

A full DPF delete for 6.7 Powerstroke is a separate, also off-road-only modification. Ignoring the DPF after an EGR delete still leads to restriction and high exhaust pressure.

While removing recirculated soot keeps dry carbon out of your intake valves, oil mist from the factory crankcase ventilation system can still cake inside your intercooler piping. Pairing your project with the CCV reroute for 6.7 PowerStroke ensures your entire air intake tract remains completely dry and sludge-free.

FAQs

What amount of coolant will you be losing during the install?

Expect to drain 2-3 gallons. Residual coolant in the cooler adds another quart that spills during removal. Capture and filter what you can; top off with fresh Motorcraft-spec coolant after the bleed.

Will an EGR delete cause a check engine light?

Yes, unless you load a proper off-road tune onto the ECM. The ECM looks for EGR flow and temperature data. Missing signals set P0401, P0402, P2457, and related codes. A correct tune disables those monitors.

Can an EGR delete affect warranty coverage?

Yes. Any emissions-related modification voids the applicable portion of the factory powertrain warranty. Dealers can and do deny claims once the cooler is missing.

If a bolt breaks while removing, what should you do?

Stop. Apply penetrating oil, use a quality extractor set, or seek professional help. Drill on center, extract the broken piece, and replace the fastener with the correct grade and length. Never leave a broken stud in the head or manifold.

What's the difficulty level in installing a 6.7 Powerstroke EGR delete kit?

It is suitable for intermediate DIY mechanics who have the right tools (metric tools, coolant systems, basic electrical connectors, etc.) and time. Seized bolts and the mandatory tune raise the difficulty for absolute beginners.

Is an EGR delete legal on a street driven 6.7 Powerstroke?

No. Federal law and most state inspection programs prohibit it on any vehicle driven on public roads. Off-road and competition use only.

Can you install an EGR delete kit without removing the intake?

No. The cooler sits under and behind the intake plumbing. Full access requires intake removal on every 2011-2019+ 6.7.

Will you need to drain coolant to install an EGR delete on a 6.7 Powerstroke?

Yes. The EGR cooler is part of the cooling circuit. Opening the lines without draining creates a large coolant spill and air locks later.

Is a tune necessary after removing the EGR from the 6.7 Powerstroke?

Yes. The factory ECM will set multiple codes and often limit power without a custom off-road calibration that disables EGR monitors. Tuning prevents fault codes and limp mode after the delete.

What is the difference between an EGR delete and a full delete kit?

An EGR delete removes only the exhaust-gas recirculation cooler and valve. A full delete also removes the diesel particulate filter and diesel exhaust fluid system. Full deletes require more extensive tuning and remain off-road only.

Does an EGR delete help with your 6.7's fuel usage?

Most owners report 1-3 mpg gains under light load once the cooler restriction is gone and the tune is optimized. But it varies from person to person depending on driving habits. Heavy towing gains appear mainly as lower EGTs and restored power rather than large economy jumps.

Can I reverse an EGR delete and reinstall the factory EGR later?

Yes, if you keep every original part, gasket, and fastener. The process is the reverse of the delete and still requires a return to a stock or emissions-compliant tune.

Summary

This guide covered the full Ford 6.7 EGR delete instructions workflow from start to finish. Preparation, component access, coolant bypass, hardware removal, and block-off plate installation all matter. ECM tuning and a careful bleed check finish the job properly.

Always verify fitment/ tolerance specifications for your model year. Maintain a tidy workspace and work patiently and in an organized manner throughout the project.

Legal reminder: EGR deletes are intended for off-road and competition use only. Street-driven vehicles must comply with federal and local emissions laws at all times.

For quality kits and reliable Ford 6.7 EGR delete kits built for 2011 through 2019+ Powerstroke trucks, visit egrperformance.com today. It provides the precise fitment and lifetime support. Successfully bypassing the EGR cooler gives your Super Duty engine long-term reliability and cooler operating temperatures.

If you are considering a full-system transformation including DPF and DEF removals, read our comprehensive overview of 6.7 PowerStroke deletes.

More Reading

• Is Ford 6.7 a Good Engine?
• 6.7 Power Stroke Years to Avoid
• 2011-2016 Ford 6.7 Powerstroke Buyer's Guide