The 6.7 Powerstroke engine is widely popular among diesel enthusiasts for its reliable performance and durability. However, like many diesel engines, one of its components has sparked controversy among car owners: the exhaust gas recirculation (EGR) system.
More and more car owners have chosen to get rid of the troubles caused by this system through "EGR delete". But can this seemingly permanent modification plan really be the ultimate answer to the problem? This article will explore the 6.7 Powerstroke EGR delete pros and cons to help you make an informed decision.
What Is 6.7 Powerstroke EGR Removal?
The EGR system can be regarded as a recycling system for the car. Its main purpose is to reduce the emission of toxic gases such as nitrogen oxides (NOx). It recirculates part of the exhaust gas back to the intake manifold, thereby reducing the maximum temperature and reducing the synthesis of toxic gases.
However, this design with environmental protection as its original intention is like a double-edged sword.
Repeatedly circulating high-temperature exhaust gas may clog the exhaust system and affect engine efficiency, etc. Therefore, many car owners, including those of 6.7 powerstroke engines, will delete the EGR system.
There are many such aftermarket parts on the market—EGR delete kits. Their purpose is to stop the exhaust gas from re-entering the engine, thus eliminating many problems. For many 6.7 Powerstroke owners, this is seen as a way to improve engine life and performance.
Benefits of Deleting the 6.7 Powerstroke EGR
Removing the EGR system from the 6.7 Powerstroke may have environmental regulations that limit it. But it does bring many benefits to vehicle performance and long-term maintenance.
1. Save a lot of money
If you remove the EGR, you can save a lot of money. We will calculate from three aspects: fuel consumption, cleaning cost, and replacement cost.
Assuming total mileage = 300,000 miles:
Savings after removing the 6.7 Power Stroke EGR: $8783.72.
（1）Fuel savings
MPG (miles per gallon) +5%, saving 952.38 gallons per 300,000 miles (≈ $4761.9 in fuel costs).
Fuel efficiency +4.76%, longer driving range.
(2) No cleaning cost
When the EGR is not removed, it usually needs to be cleaned every 20,000 miles. And the cost of each cleaning is $150 (≈ $2250).
After removing the EGR, there is no cleaning cost, no smoke accumulation, and the intake is clean.
(3) No replacement cost
If the EGR is not removed, it will become clogged or not work every 150,000 miles and must be replaced.
The parts cost was $1,071.82 and the labor cost was $700. So without removing the EGR, the replacement cost would have been around $1,771.82.
With the EGR removed, there is no replacement cost and no more clogging or EGR DTCs!
2. Extended Engine Life
Since EGR works by pushing exhaust gas into the intake manifold, removing EGR minimizes carbon deposits in the intake manifold and cylinders. This prevents EGR coolers and valves from clogging, which extends the life of the engine.
3. Cooling System Relief
With the EGR system removed, there is no need to cool the recirculated exhaust gas. This greatly reduces the load on the cooling system, allowing it to operate more reliably.
4. Improved Fuel Economy
Without EGR, there is less stress on the engine, which improves fuel efficiency. Many owners report a slight increase in miles per gallon (MPG) after performing an EGR delete.
5. Easy-to-Install EGR Delete Kits
Many EGR delete kits are easy to install. These kits usually come with detailed instructions to ensure that the installation process goes smoothly.
Disadvantages of Deleting the 6.7 Powerstroke EGR
While deleting the EGR system on your 6.7 Powerstroke has attractive benefits, it also comes with significant risks and trade-offs. Here are some potential drawbacks.
1. Potential emission violations and fines
If your state requires regular emissions testing, deleting the EGR could cause your vehicle to be disqualified and unlegally on the road. In addition, if law enforcement finds that your vehicle has been illegally modified for emissions, you may face fines. Therefore, before performing an EGR deletion, be sure to confirm the legal requirements in your area.
2. Increased nitrogen oxide emissions and affected air quality
The main function of the EGR system is to reduce NOx (nitrogen oxides) emitted by the engine. It is one of the important factors causing smog, acid rain and air pollution. Therefore, after removing EGR, NOx emissions will increase significantly.
3. Possible vehicle warranty voiding
Ford and most automakers have clear warranty terms that stipulate that any modification involving emission control may void the warranty. If the EGR deletion is discovered, warranty service may be denied. Therefore, it is recommended that you confirm with your automaker first.
4. May Affect Future Resale Value
Removing EGR may affect your vehicle's appeal in the used market. Many buyers may be reluctant to purchase an emissions-modified vehicle because they may need to be restored to factory condition to be road legal. This could complicate the sale of your truck.
Weighing the Pros and Cons of 6.7 PowerStroke EGR Removal
Deleting the EGR system from the 6.7 PowerStroke certainly brings many benefits, but this change also comes with some risks.
Pros:
- Saves a ton of money
- Extended engine life
- Easy to cool the system
- Improved fuel economy
- EGR delete kit is easy to install
Cons:
- Legal issues
- Environmental impacts
- Vehicle warranty may be voided
- Resale value impacted
Final advice: rational trade-offs, careful decisions
FAQs about 6.7 Powerstroke EGR Removal
1. Will removing the EGR void my Ford warranty?
Yes, if a Ford dealer finds someone has tampered with the emissions system, they can deny a warranty claim.
2. Will I be able to pass an emissions test after removing the EGR?
Unlikely, increased NOx emissions may be detected after removing the EGR system.
3. Will removing the EGR improve fuel economy?
Yes, without the EGR system, the engine is less stressed, which improves fuel efficiency.
4. How much does it cost to remove the 6.7 Powerstroke EGR?
Removal cost: EGR removal kit $79.99~$139.99, professional installation labor $350, tuning $1100.
5. How much horsepower does removing the EGR add?
A 6.7 Powerstroke removal can add up to 20 horsepower, depending on modifications and tuning. Below is a horsepower and torque comparison before and after EGR removal (2020-2023 6.7 Powerstroke diesel engines).
6. Are there any fault codes for EGR failure?
Yes. If an EGR failure occurs, the following diagnostic fault codes may appear when using an OBD2 scanner:
- P0403: Circuit Fault
- P0400: Flow Fault
- P0401: Insufficient Flow
- P0402: Excessive Flow
7. How long can the deleted 6.7 Powerstroke last?
If the deleted 6.7 Powerstroke engine is properly maintained, its life will be longer than before the deletion, but it also depends on personal driving habits.
