How to Install a 2011-2019 6.7 Powerstroke EGR Delete Kit – Step-by-Step

Learn how to safely remove the factory cooler and install a 6.7L Powerstroke EGR delete kit with our detailed instructions, covering required tools, step-by-step procedures, and expert mechanic tips.

Introduction to the 6.7 Powerstroke EGR Delete

Thank you for choosing the SPETUNER 6.7 powerstroke egr delete kit. Designed to maximize your engine’s potential, this kit eliminates the restrictions caused by the stock Exhaust Gas Recirculation (EGR) system. By improving airflow, reducing soot buildup, and minimizing long-term maintenance, the EGR delete is a powerful upgrade for off-road and race enthusiasts.

Important Note: This modification is for off-road and race use only and may not comply with emissions regulations for on-road vehicles in the US and Canada. Before installing, familiarize yourself with local laws to ensure compliance.

Specifics for 2011 and 2012 F250/F350 Models

We see a lot of owners searching specifically for a 2012 F250 6.7 EGR delete kit or 2011 F250 delete instructions. If you drive an early-generation 6.7L Powerstroke (2011-2014), the core EGR removal process is exactly the same as the 2015-2019 models.

The only minor difference is the turbo pedestal and piping layout underneath, but the EGR cooler mounting points on top of the engine block match perfectly. Our SPETUNER block-off plates are precision CNC-machined to seal perfectly across all 2011-2019 model years.

Tools and Materials You’ll Need

Essential Tools

• Socket Wrenches: Sizes 7mm, 8mm, 10mm, and 13mm.
• Pliers: For coolant clamps and small parts.
• Sawzall: Optional, for cutting stubborn exhaust brackets if needed.
• Screwdrivers: Both flathead and Phillips.
• Penetrating Fluid (WD-40/PB Blaster): To loosen seized exhaust bolts.
• Drain Pails: To catch coolant.
• Safety Gear: Gloves and safety glasses.

SPETUNER EGR Delete Kit Components

• Blocker Plates: Seal off the EGR system exhaust and intake ports.
• Gaskets: Ensure airtight connections to prevent exhaust leaks.
• Bolts and Washers: Secure the plates and components.
• Hoses and Clamps: Replace stock hoses to reroute the coolant properly.

Before beginning, inspect your EGR Delete Kit for 2011-2019 Ford 6.7L Powerstroke Diesel and tools to ensure everything is ready.

Preparation

Safety First

1. Park your vehicle on a flat surface and engage the parking brake. Ensure the engine is completely cool.
2. Wear safety gloves and goggles to protect yourself during the process.

Disconnect the Batteries

• Use a wrench to disconnect the negative terminals on both batteries. This prevents electrical shorts or accidental startups.

Lift the Vehicle (Optional)

• Use a hydraulic jack or ramps to raise the front of your truck for better access to the lower radiator hoses.
• Place drain pails beneath the radiators to catch the coolant you’ll drain shortly.

Step 1: Drain the Coolant

Draining the coolant is crucial to avoid spillage when removing the EGR components. The 6.7L has two cooling systems; you need to drain the primary (primary radiator) system.

Locate the Radiator Drain Plugs: Position drain pails underneath the driver's side lower radiator area.

Open the Plugs: Use pliers to gently turn and pull out the drain plugs (usually plastic). Take care not to damage them.

Remove Coolant Caps: Open the radiator and coolant reservoir caps (degas bottle) to allow air to flow and speed up drainage. Ensure the coolant is fully drained before moving to the next step.

Step 2: Remove the Air Intake System

Removing the air intake creates the space you need to access the EGR system on the passenger side of the engine.

Unbolt the Air Intake Box: Use an 8mm socket to remove the bolts securing the intake box. Disconnect the mass airflow (MAF) sensor carefully.

Remove the Intake Pipe: Loosen the clamp with a 7mm or 8mm socket and gently pull the pipe off the throttle body/intake manifold.

Clear the Workspace: Remove any additional hoses or brackets attached to the intake system.

Step 3: Remove the EGR System

Access the EGR System

Disconnect Coolant Lines: Identify the hoses connected to the EGR cooler and remove the spring clamps using pliers.

Unplug Wiring and Sensors: Carefully disconnect all sensors (EGR bypass valve, EGR temperature sensor) and wiring harnesses. If access is tight, remove any obstructing brackets.

Remove the EGR Cooler

Unbolt the Cooler: Remove the exhaust manifold bolts and the mounting bolts securing the cooler to the engine block. Use penetrating fluid if the exhaust bolts are rusted or stuck.

Handle Stubborn Components: If necessary, use a Sawzall to cut obstructing brackets, ensuring you don’t damage surrounding parts.

Extract the Cooler: Wiggle the cooler loose and carefully pull it out. Avoid tangling with the injector wiring harness or other sensitive fuel lines.

Step 4: Install the SPETUNER EGR Block Off Plates Kit

Install the Blocker Plates

Position the Plates: Clean the mating surfaces thoroughly. Place the first blocker plate on the intake manifold where the EGR valve routed. Use the provided gaskets to ensure a proper seal.

Secure with Bolts: Fasten the plates with the provided bolts and washers. Ensure they’re tightened to the factory recommended torque.

Repeat for the Exhaust Port: Install the heavy-duty exhaust block-off plate on the exhaust manifold side, following the same steps.

Reassemble Components

Reconnect Coolant Lines: Use the supplied coolant reroute hose to bypass the old cooler. Secure it with the provided hose clamps, ensuring they are properly seated to prevent coolant leaks.

Reinstall the Intake System: Reattach the intake pipe and box, securing all clamps and reconnecting the MAF sensor.

Refill Coolant: Add the appropriate Motorcraft coolant to the radiator and reservoir. Replace the caps securely.

Reconnect Batteries: Reconnect the negative terminals to restore power to the ECM.

Step 5: Testing and Troubleshooting

Initial Checks

1. Turn the ignition to the "on" position without starting the engine. Check for warning lights.
2. Start the engine and let it idle. Listen for unusual exhaust leaks (a ticking noise) and inspect for coolant leaks around the new reroute hose.

Road Test

• Take the truck for a short drive. Monitor performance, turbo boost, and engine coolant temperatures.

If issues arise, revisit the installation to ensure all block-off plates are torqued down and hoses are properly secured to avoid common 6.7 Powerstroke problems.

Step 6: Tune Your Engine

After following these Ford 6.7 EGR delete instructions, proper tuning is absolutely essential. Without a tune, your truck will immediately go into limp mode and throw multiple check engine lights.

Choose a Tuning Solution: Use a tuner designed for deleted 6.7 Powerstroke engines, such as SPETUNER-compatible EZ Lynk or SCT devices tailored for the 6.7L platform.

Install the Tuner: Follow the tuner manufacturer’s instructions to flash the engine’s ECU and shut off the EGR parameters.

Test the Results & Legal Considerations

Conduct another road test, monitoring fuel efficiency, power output, and boost pressure.

Legal Considerations: Installing an EGR delete kit is strictly illegal for on-road use due to federal emissions regulations. Always ensure that this modification complies with local laws and is used exclusively for off-road, farm, or competition racing purposes.

Conclusion

With this step-by-step guide, your 6.7L Powerstroke is ready to achieve unparalleled off-road performance. The SPETUNER EGR Delete Kit is designed to enhance horsepower, airflow, and reliability when installed and tuned correctly.

For any assistance or questions regarding your 2011-2019 F250/F350 build, reach out to our team at service@spetuner.com. Happy modding!

SPETUNER—Unleashing the potential of every diesel engine!

FAQs

Q1: Is the EGR delete worth it on a 6.7 Powerstroke?
A1: Yes, deleting the EGR system can enhance engine performance by improving airflow, reducing soot buildup, and increasing reliability for off-road or race use. However, it is not legal for on-road use in most regions.

Q2: Do you need a tuner for EGR delete on a 6.7 Powerstroke?
A2: Yes, a tuner is essential after an EGR delete to recalibrate the engine’s computer. This prevents error codes, optimizes performance, and ensures smooth operation.

Q3: Can you delete a 6.7 Powerstroke yourself?
A3: Yes, with the right tools, a high-quality EGR delete kit, and a detailed guide, you can delete the EGR system yourself. However, mechanical knowledge and experience are recommended.

Q4: How much HP does deleting a 6.7 Powerstroke add?
A4: Deleting the EGR is a proven way to increase 6.7 Powerstroke horsepower, typically adding 20-30 HP depending on the tuning and other modifications made to the engine.

Q5: Will EGR delete improve fuel mileage?
A5: Yes, by reducing engine workload and improving airflow, an EGR delete can improve fuel mileage, but results vary depending on driving conditions and additional modifications.

Q6: What are the risks of deleting the EGR on a 6.7 Powerstroke?
A6: Understanding the risks of deleting the EGR is important; they include voiding warranties, potential legal issues for on-road use, and the need for proper tuning to prevent engine damage or performance issues.

Q7: How long does it take to install an EGR delete kit on a 6.7 Powerstroke?
A7: Installation typically takes 4 to 6 hours, depending on your experience and familiarity with the process.

Q8: What tools are required for a 6.7 Powerstroke EGR delete?
A8: Common tools include wrenches, sockets, pliers, a Sawzall for stubborn parts, screwdrivers, and drain pails for coolant removal.

Q9: Does deleting the EGR void my truck's warranty?
A9: Yes, performing an EGR delete can void the manufacturer’s warranty, as it modifies the vehicle’s emissions system.

Q10: Can I still pass emissions testing after an EGR delete?
A10: No, deleting the EGR system is not compliant with emissions regulations, and the vehicle will likely fail emissions testing in most areas.

Lars

Diesel Performance Engineer | 15+ Years EXPERIENCE

Lars has spent over 15 years building and tuning more than 1,000 diesel engines. He specializes in engine durability and high-performance calibrations for Powerstroke, Cummins, and Duramax platforms. At SPEtuner, he cuts through the noise to provide clear, actionable insights on everything from DPF/EGR solutions to custom EFI Live tuning. His goal: solve the $10,000 "Limp Mode" traps and make every truck bulletproof.

"Empower Your Beast: Run Cooler, Pull Harder, Last Longer."