6.7 PowerStroke EGR Delete Problems You Should Be Aware Of

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Written By Thomas Anderson

‘As a PowerStroke owner or as a diesel enthusiast, you must have come across the famous conversation on EGR delete and the frustrations with the exhaust system. If you’re considering EGR delete for your truck, we’ll get you to go through this discussion on 6.7 PowerStroke EGR delete problems

The EGR delete can reduce horsepower and drastically increase the temperature of your fuel system. It’s illegal to delete the system in the United States, and you’d fail in the emission tests without it. Many have faced engine knocking issues after EGR delete. Plus, the process is of high cost. 

To save fuel economy and increase engine power, truck users mostly perform EGR delete. But as the saying goes, it’s always better to be safe than sorry.

Read along to find out if EGR delete is worth it or not! 

The 6.7 PowerStroke Engine and The Exhaust Emission System 

The PowerStroke 6.7L version was the first engine manufactured directly by Ford, previous ones were by Navistar International. 

This fourth-generation diesel engine has been powering the Ford trucks providing impressive torque and horsepower.

Nonetheless, the engine isn’t an unmixed blessing. Be it Ford or any other manufacturer; modern generations are bound to retain a proper emission exhaust system. 

And the engine depending heavily on the exhaust system can get problematic at times. 

Prioritizing environmental protection, the emission control system has been designed to reduce the volume of harmful gases produced by cars.

Some of the main parts encompassing this system are:

  • EGR (Exhaust Gas Recirculation)
  • DPF (Diesel Particulate Filter),
  • SCR (Selective Catalytic Reduction)

One of the most discussed problems of the 6.7 PowerStroke engine is issues with the EGR cooler system. 

There have been multiple instances of carbon clogging the cooler valve resulting in over-heating the system. 

While replacing the EGR cooler might be an option, some users opt for deleting the total EGR system. Some undergo the procedure to increase fuel economy. 

In this article, we’re going to introduce what an EGR delete means, followed by an in-depth discussion of the problems caused by the deletion and if there are any alternative methods you can adopt.

Let’s get started! 

What Does An EGR Delete Procedure Mean

The EGR or the Exhaust Gas Recirculation technique assists in reducing toxic gas emissions, specifically Nitrous oxide. Exhaust from the engine is redirected through the cylinders back into the engine. 

But a clogged exhaust system can hamper engine efficiency, for which the EGR delete is an ongoing debate among users. 

Since many people desire to increase their engine power, there are delete kits particularly designed to get the work done. These are generally known as aftermarket parts.

Using the EGR delete kit, you can remove the EGR valve and stop the exhaust redirection process. 

A lot of people also go for deleting the DPF or Diesel Particulate Filter system, and there’s a wide misunderstanding among users regarding the two systems.

EGR and DPF are a part of the exhaust system, but their functions are unique. DPF has more to do to eliminate physical particles than toxic gas. However, some prefer to delete both systems altogether. 

Although user forums suggest that there have been engine and fuel advantages, research shows that deleting the 6.7 PowerStroke EGR brings more problems than benefits. 

6.7 PowerStroke EGR Delete Problems

The 6.7L engine has its flaws, and many people believe in deleting the EGR to enhance the engine performance. 

But it’s imperative to look into the whole EGR delete discourse with a wider lens because getting rid of the exhaust system often does more harm than good. 

Using the EGR delete kits has its own set of problems. 

The following are the most common issues you’d have to deal with for an EGR delete-

1. Reduced Horsepower

Your vehicle engine can use more power efficiently if it gets provided with fresh air in the combustion chamber.

The EGR system can help in mixing clean air with fuel.

But to increase the intake of air furthermore, previously, users would delete EGR to create more space in the chamber.

This is not an available option for the modern generation system. Unlike the older models, you won’t be allowed to bypass the products or kits and modify the air intake rate. 

Hence instead of increasing power for the engine, using an EGR delete kit at present would result in reducing your vehicle’s overall horsepower.

2. Increased Temperature

The most significant role played by an EGR for a diesel engine system like the 6.7 PowerStroke is to maintain the temperature throughout the fuel system.

These engines are specifically designed to recirculate the cooled-down exhaust gas into the system. 

Now, if you delete the EGR, it messes up the whole procedure and results in temperature rise for the exhaust gas. 

This will have a strong impact on your engine’s all-around cooling system. 

3. Knocking Engine

The engine is said to be knocking when the fuel rate is uneven inside the fuel cylinders.

A sudden change of temperature caused by an EGR delete can result in a knocking engine.

Moreover, deleting the EGR would also mean that your oil quality and fuel mixture alter and it might have direct consequences on the whole fuel system and the engine.

If this goes on for a long time, the engine can eventually cease to function. 

4. Illegal Street Driving

Running your vehicle in the main streets after deleting the EGR would be a Federal crime in the United States.

The emission rules governed by the Federal do not allow this modification. 

With a deleted EGR, you can only be on the off-roads, and this restriction isn’t helpful at all in the long run. 

5. Failing Emission Tests

If the state requires an emission test you reside in, you’ll fail it without any doubt if the EGR is deleted. 

Based on your exact location and your vehicle type, you can be fined about $10,000. 

Continuing to use the vehicle with a bypassed EGR would translate to putting out more money on law enforcement workers. 

6. Extra Cost

The EGR and all the components of the exhaust gas system are designed and incorporated with the entire engine system.

Taking out parts or deleting any of the systems isn’t a mere task; it requires expert intervention.

Even if you intend to do it on your own, the EGR delete kit alone costs about $200. And a mechanic installing it means more cash needs to be spent.

On the other hand, if you decide to sell your car or truck, your resale value will decline drastically if the EGR is deleted.

Can There Be Actual Performance Gains Through An EGR Delete?

There can be performance gains achieved through deleting EGR. But in the long run, the issues coming with it might outrun the benefits. 

Here are some of the benefits you might enjoy by taking proper steps for an EGR delete procedure.

1. Probable Benefits

Engine performance can get enhanced following an EGR delete.

2. Increased Engine Power- 

EGR valves are said to limit the power of engines. To resolve this, people carry out the EGR delete process to get a more powerful engine that can deliver mileage. 

3. Fuel Efficiency- 

Without an EGR valve, your engine has to use less power to provide the same amount of power, and you might also have less amount of fuel needed to burn on the chamber. 

Thus, it can help in retaining fuel efficiency and help improve fuel economy.

Regardless, you should be extra careful if you are indeed going for an EGR delete.

4. Steps You Should Consider

One wrong step in this deletion process can cost you very heavily. We propose you keep these few conditions in your mind while going for an EGR delete. 

5. Following the right delete method

As mentioned earlier, many people try to delete both the EGR and DPF systems all at the same time, but you might end up damaging the other parts badly 

doing so.

Professionals suggest undertaking the EGR delete procedure before 

the DPF one.

Again, when using delete kits, make sure you or your mechanic are using the correct one designed for your vehicle.

For Ford Powerstroke 6.7 ones, the delete kit from Bully Dog and Mini Maxx companies are widely used. 

6. Using a proper tuner

EGR tuners help the vehicle to adjust to the change and for the whole system to function properly. Most delete kits come with a tuner to ensure the work 

gets done well.

If you do end up performing EGR delete, it’s crucial to use a proper tuning method to save your engine from failing. 

As a custom tuner, the SCT X3 type tuner is recommended for use, especially for trucks. 

Overall Pros and Cons of 6.7 PowerStroke EGR Delete Problems

Since we’ve mentioned some of the benefits of EGR delete along with discussing the broad range of problems your 6.7 Powerstroke would have to deal with, it’s important to have a mental map of the overall pros and cons of the EGR delete. 

Pros of EGR delete for 6.7 PowerStroke-

  • Probable increase in engine power
  • Fuel efficiency and improvement in fuel economy

Cons of EGR delete for 6.7 PowerStroke-

  • Reduces overall horsepower
  • Exhaust gas temperature gets increased
  • Illegal in the United States and will fail Federal emission tests 
  • Results in Engine Knocking
  • Expensive to carry out 

Even if you get a more powerful engine after EGR delete, the problems are far more huge and enough to keep you super stressed in the long run. So we’d personally suggest not to go for EGR delete if you’re not ready to tackle all the issues. 

Frequently Asked Questions

How much additional horsepower can one get through EGR delete?

If you have all clean air and fuel intake, you might get about 1 to 2 extra Horsepower added through EGR delete. To increase your horsepower more, adopting other trim packages can be an option, but EGR delete wouldn’t give you much more than this. 

Is there a fault code for a faulty EGR?

Yes! The fault code or DTC code P0401 refers to a possible exhaust system cooler or EGR cooler. 

Why is removing the EGR valve an incomplete step?

EGR delete denotes only removing the valve, and even though you might get a more powerful engine, the benefits will run out soon because EGR is a part of a broader system.

And so, taking out any part of the entire emission system would be an incomplete step. 


Relying on a few cases of engine efficiency stories to make your final decision can disrupt your peaceful truck experience, for which you can now take the best decision by being aware of the 6.7 PowerStroke EGR delete problems.

Modifying your automobile should always be in the best interest of your car, but environmental protection is a responsibility that should be respected as well. We hope this article will help you in making the best choice for your PowerStroke.

Good luck!