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EGR Delete DIY: Installing the 6.0 Powerstroke Kit Like a Pro

  • Author: SPELAB Mechanical Engineer (focusing on car modification for 10 years)

The 6.0L Powerstroke diesel engine in Ford Super Duty trucks from 2003 to 2007 is known for its reliability issues, which stem from its problematic exhaust gas recirculation (EGR) system. One way owners address these issues is by performing an EGR delete, which involves removing the EGR system components.

In this article, we will provide a step-by-step guide to performing an EGR delete on the 6.0L Powerstroke "like a pro" with the help of an aftermarket EGR delete kit. We will explain the need for an EGR delete on these engines and take you through the entire installation process.

Why Perform an EGR Delete on the 6.0L Powerstroke?

The 6.0L Powerstroke engine was plagued with issues related to its factory EGR system, which would pull hot exhaust gases back into the intake manifold to reduce NOx emissions as mandated. However, this system was poorly engineered and proved unreliable. Common problems included stuck or leaking EGR valves and carbon buildup inside the intake and on top of the pistons. Over time, this could lead to a loss of power and efficiency. A 2003-2007 6.0 Powerstroke egr delete kit avoids these issues by deleting the faulty EGR system.

Installing the 6.0 Powerstroke Kit Like a Pro

The benefits of an EGR delete include:

  • Increased power and torque output
  • Reduced engine temperatures
  • Elimination of repetitive EGR system error codes
  • Improved fuel efficiency
  • Longer engine life

 Choosing the Right EGR Delete Kit

With several online options, choosing the right EGR delete kit can get a bit confusing. We recommend the SPELAB EGR delete kit for the 6.0L Powerstroke as it is designed to provide a complete and professional solution.

Some key things to look for in a quality kit include:

  • Premium quality bungs, plates, and gaskets for a leak-proof sealed system
  • Appropriately sized tools like a torque wrench for proper tightening  
  • Lifetime tech support in case you need help during the install
  • Affordability without compromising quality

SPELAB's 6.0L Powerstroke EGR delete kit checks all these boxes. It is a complete 6.0 powerstroke egr delete kit with everything needed to remove the EGR system properly. Their reputation as the top supplier of diesel performance parts makes them the best place to source these kits. Also, they are offering huge discounts right now, so don’t miss out!

Installing the EGR Delete Kit

Now, you'll begin putting the aftermarket EGR delete components in place of the stock ones. Here are the main installation steps:

  • EGR plate:Clean the intake manifold mounting surface and bolt the DELETE EGR plate to the mounting holes with thread sealant.  
  • Blocker plate:On the EGR cooler port, install the blocker plate and secure it tightly to seal this opening.  
  • Cap bolts: Use these bolts to cap the remaining openings, like the EGR valve port on the intake manifold.  
  • Boost tubes:Reconnect the turbo outlet and inlet pipes that were previously connected to the EGR cooler.
  • Plug wires: Securely plug any sensor wires like EGR temperature or DPFE into the delete kit harnesses.

At this point, you've completed blocking all the necessary ports and openings that were initially used by the EGR delete 6.7 cummins components. Double-check that everything is sealed properly before moving forward.

Installing the 6.0 Powerstroke Kit Like a Pro

Finishing Up and Reassembling

A few final touches are needed before putting the engine back together: 

  1. Install new coolant: Fill the coolant reservoir and bleed air from the system after disconnecting it earlier.  
  1. Fire up the engine: Crank it over briefly to check for leaks while keeping an eye out for any residual air bubbles escaping the coolant system.
  1. Torque all bolts: Go back through with the torque wrench and tighten everything to spec, paying close attention to hose clamps.
  1. Test drive: Take it for a short drive and monitor gauges to verify no error codes come up related to the deleted EGR system.

Reinstall any other components you had to remove, like the air intake tube, electric fan shrouds, etc. Top off all fluid levels, and you're done! Your 6.0L Powerstroke should now run smoother and stronger without the factory EGR holding it back.

Benefits of an EGR Delete

With the EGR system properly removed, you'll start experiencing the advantages right away:

  • Noticeably improved throttle response and turbo spool.
  • Higher exhaust gas temperatures indicate more complete combustion.
  • Louder exhaust notes as gases no longer recirculate into the manifold.
  • Reduced visible smoke on acceleration thanks to improved combustion.
  • Elimination of that annoying "EGR valve cycling" noise.
  • In the long term, you will see reduced carbon buildup inside the engine.
Installing the 6.0 Powerstroke Kit Like a Pro



In conclusion, performing an EGR delete on the 6.0L Powerstroke with an aftermarket kit is undoubtedly the best thing owners can do to resolve the engine's inherent problems and unlock its full potential. The discounted SPELAB EGR delete kit and detailed instructions make the task quite manageable for DIYers. With some time and effort put into a professional install, owners can say goodbye to the faulty EGR system once and for all while breathing new life into their 6.0L diesel. Increased performance, efficiency, and longevity are well worth it in the end.

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