Powerstroke diesel engines from Ford are renowned for their reliability, durability, and outstanding towing capacity. However, as with most modern diesel engines, the introduction of emissions control systems such as the Exhaust Gas Recirculation (EGR) system often detracts from the performance of the engine. The EGR system recirculations exhaust gases back into the intake to lower NOx emissions. Although it is effective in reducing emissions, it can also have a negative impact on the efficiency of the engine, carbon buildup, and even performance issues. This is where EGR delete kits come in, offering a solution for truck owners seeking improved performance. In this article, we will discuss the benefits of EGR delete kits for Ford’s 6.0L, 6.4L, and 6.7L Powerstroke engines.
What is an EGR Delete Kit?
An EGR delete kit is a modification which removes or bypasses the EGR system on your diesel engine. In this way, your engine no longer recirculates exhaust gases. This restores the air quality of the intake, improves combustion efficiency, and, in general, improves the overall performance of your engine. Such kits usually consist of block-off plates, gaskets, hardware, and installation instructions. Depending on the vehicle, additional tuning may be required to ensure the engine runs smoothly without the EGR system in place.
6.0L Powerstroke EGR Delete Kit
The 6.0L Powerstroke in the 2003 to 2007 Ford Super Duty truck has excellent power and high torque but is most notorious for a bad EGR system. Coolant leaks that lead to an overheated engine can occur through failures of the 6.0L Powerstroke EGR cooler. Should such failures take place, then severe damage might be caused to the engine- heads may get warped or turbochargers ruined.
An EGR delete kit for the 6.0L Powerstroke avoids many of the EGR system problems, such as coolant contamination and carbon buildup, and removes the system to enhance throttle response, prevent excessive soot buildup in the intake, and generally increase performance and reliability of the engine. A proper tune is necessary after installation to prevent check lights and ensure optimal performance from the engine.
6.4L Powerstroke EGR Delete Kit
The 6.4L Powerstroke engine, found in 2008 to 2010 Ford Super Duty trucks, is another diesel engine that benefits from an EGR delete kit. The 6.4L engine has a better design than the 6.0L but still suffers with the EGR system. One area of concern is the EGR cooler on a 6.4L, which tends to clog up and fail quickly, causing the engine to overheat and become covered in extra carbon buildup that can reduce the efficiency of a turbocharger, thereby affecting performance.
An EGR delete kit for the 6.4L Powerstroke can eliminate this problem, resulting in smoother-running performance, greater power, and less chance of engine problems attributed to EGR failures. Furthermore, elimination of the EGR ensures minimal chances of soot formation in the intake of the engine and the turbo. All this would mean better fuel consumption, enhanced power delivery, and lesser long-term maintenance costs. As with the 6.0L, the ECU needs to be reprogrammed for the 6.7L Powerstroke for everything to function properly after the installation of the delete kit.
6.7L Powerstroke EGR Delete Kit
More recently, the 6.7L Powerstroke engine, from 2011 and later models of Ford Super Duty trucks, is a better diesel engine and has a better EGR system. Although that engine is considered to be of better overall performance and reliability, some owners also choose an EGR delete kit to further tap into their potential.
The 6.7L Powerstroke EGR system is relatively less prone to failure than both the 6.0L and 6.4L systems, although it can present some performance-reducing difficulties. The passage of time reduces the effectiveness of the EGR cooler, becoming clogged up with soot, which produces lower power along with higher temperatures in the exhaust and lower performances in the turbocharger. Intake carbon deposit can also further reduce airflow resulting in lower combustive efficiency.
Truck owners who install an EGR delete kit for the 6.7L Powerstroke will simply delete the EGR system, but will greatly enhance air flow into the combustion chamber and thus provide better efficiency in combustion. This modification can include improved throttle response, added horsepower, and better fuel economy. For the 6.0L and 6.4L engines, as well, tuning is essential to ensure proper operation after deletion of the EGR system.
Advantages of EGR Delete Kit
Whether you drive a 6.0L, 6.4L, or a 6.7L Powerstroke engine, the removal of the EGR system has given you the benefits as follows.
Improved Engine Performance: With removal of the EGR system, the engine has a more optimum way of burning the fuel thus leading to much better horsepower and torque.
The fuel efficiency improved since the removal of the exhaust gases will eliminate the intake at optimal temperatures while improving fuel combustion, thereby offering higher miles per gallon.
Reduced Carbon Buildup: EGR systems are notorious for causing carbon buildup in the intake and turbocharger. An EGR delete kit eliminates this problem, reducing maintenance costs and improving overall engine longevity.
More Reliable Engine: In engines like the 6.0L Powerstroke, EGR coolers are prone to failure. Removing the EGR system can prevent costly repairs associated with EGR cooler and valve failures.
Considerations
Consider the following first before installing your EGR delete kit:
Do not install, especially if this falls under locations where emissions have stricter regulations—California, as one example.
Voiding warranties: Installing any kit may even cause you to lose your manufacturers’ warranty at times. Refer to your manufacturer or dealer and see if installation is allowed prior to doing such a modification.
Reprogramming Required: After installing the EGR delete kit, the vehicle’s ECU will need to be reprogrammed to ensure proper engine operation and to avoid check engine lights or other issues.
Conclusion
An EGR delete kit can provide significant performance benefits for your 6.0L, 6.4L, or 6.7L Powerstroke engine by eliminating the emissions system that can hinder engine efficiency and performance. An EGR delete kit will help you achieve the most from your Powerstroke engine if you want to enhance throttle response, increase horsepower, or eliminate carbon buildup. Nevertheless, there are always considerations on the legal and warranty aspects of doing this and proper installation and tuning to maximize the effects.
