How to Install a 6.7L Powerstroke EGR Delete Kit - Complete Guide

Learn how to install a 6.7L Powerstroke EGR delete kit with our comprehensive guide. Discover the benefits, required tools, step-by-step instructions, and answers to common questions. Optimize your truck's performance with our expert tips and recommendations.

1. Introduction

Overview of EGR Delete

The Exhaust Gas Recirculation (EGR) system helps reduce nitrogen oxide emissions by recirculating a portion of the exhaust gas back into the engine's intake. While this is beneficial for emission control, it can also lead to a buildup of soot and other contaminants, which may reduce engine performance over time.

Performing an EGR delete on a 6.7L Powerstroke engine can help enhance its performance. By removing the EGR system, you can improve airflow, increase horsepower, and potentially improve fuel efficiency. However, it's important to note that this modification is intended for off-road and race use only. Legal considerations must be taken into account, as EGR delete kit are not compliant with emission regulations for on-road vehicles.

Ready to improve your truck's performance? Continue reading to learn about the tools and materials you'll need for this process.

2. Tools and Materials Needed

Required Tools

To successfully perform the EGR delete on your 6.7L Powerstroke engine, you'll need a specific set of tools. Here’s a list of the essential tools:

• Wrenches and Sockets: Various sizes, including 7mm and 8mm.
• Pliers: For handling clamps and other small parts.
• Sawzall: Useful for cutting stubborn components if necessary.
• Screwdrivers: Both flathead and Phillips.
• Penetrating Fluid: Helps to loosen stubborn bolts.
• Drain Pails: To catch coolant during the draining process.
• Safety Equipment: Gloves, safety glasses, and any other protective gear.

Having the right tools at your disposal will ensure a smooth and efficient EGR delete process. Gather these tools before you start the procedure to avoid any interruptions.

EGR Delete Kit Components

The SPELAB EGR Delete Kit includes several components necessary for the removal and replacement process. Here’s what you’ll find in the kit:

• Blocker Plates: These are used to block off the ports where the EGR components were removed.
• Gaskets: Ensure a proper seal to prevent leaks.
• Bolts and Washers: Secure the blocker plates in place.
• Hoses and Clamps: Replace any removed hoses with new, secure ones.

Understanding what each component does will help you follow the instructions more effectively. Make sure to lay out all parts and familiarize yourself with them before beginning the installation.

Ready to begin the installation? Continue reading for the pre-installation steps to ensure your safety and the proper setup.

3. Preparation

Pre-Installation Steps

Before you start the EGR delete process on your 6.7L Powerstroke, it's crucial to take some initial steps to ensure your safety and prepare the vehicle properly.

Safety Precautions:

• Wear gloves and safety glasses to protect yourself from potential hazards.
• Ensure the vehicle is on a level surface and engage the parking brake.

Disconnecting the Negative Battery Terminals:

• This step is essential to prevent any electrical short circuits or accidental startups.
• Locate the negative terminals on both batteries and disconnect them using the appropriate wrench.

Raising the Truck:

• Use ramps or a hydraulic jack to elevate the front of the truck.
• Position drain pails beneath the radiators to catch the coolant that will be drained.

With these steps completed, your vehicle is now ready for the EGR delete process. These preparations will ensure a smooth and safe procedure.

Ready to move forward? Let’s begin with draining the coolant and removing stock components in the next section.

4. Draining Coolant and Removing Stock Components

Draining the Coolant

Draining the coolant is the first step in the EGR delete process for your 6.7L Powerstroke. Properly draining the coolant ensures that you can work on the engine without any spillage or mess.

Locate the Drain Plugs:

• The 6.7L Powerstroke has two radiators, each with its own drain plug.
• Position your drain pails beneath each radiator.

Open the Drain Plugs:

• Use pliers or small vice grips to turn the drain plugs. They rotate about 180 degrees and then pull out as you twist them.
• Be gentle, as these plugs are plastic and can break easily.

Remove the Caps:

To allow more airflow and speed up the draining process, remove the caps from the coolant reservoir and the radiators.

Draining the coolant completely is crucial to avoid any spillage when you start working on the EGR system. Make sure the drain plugs are securely opened and the coolant flows freely into the pails.

Removing the Air Intake System

Next, you’ll need to remove the air intake system to gain access to the EGR components.

Unbolt the Air Intake Box:

• Use an 8mm socket to remove the two bolts securing the air intake box.
• Disconnect the mass airflow sensor by unplugging it carefully.

Remove the Intake Pipe:

• Loosen the clamp holding the intake pipe using a 7mm or 8mm socket.
• Gently pull the intake pipe off the throttle body.

Clear the Area:

• Your truck might have additional hoses or components connected to the air intake system. Remove these as necessary.
• Set aside the air intake box and pipe in a safe place.

By removing the air intake system, you create more space to work on the EGR components. This step is vital for a smooth and hassle-free EGR delete process.

Ready for the next steps? Continue to the section on accessing and removing the EGR system.

5. EGR Removal Process

Accessing the EGR System

With the air intake system removed, you can now access the EGR components. This step involves clearing additional space and preparing the area for EGR removal.

Remove Coolant Lines:

• Identify the coolant lines connected to the EGR cooler.
• Use pliers to remove the clamps and carefully pry off the coolant lines. Set them aside.

Disconnect Wiring Harnesses and Sensors:

• Locate the wiring harnesses and sensors attached to the EGR system.
• Unplug any sensors and disconnect the wiring harnesses to free up space.
• If necessary, remove bolts holding the harness tray in place to gain better access.

Unbolt Brackets and Heat Shields:

• Remove any brackets or heat shields obstructing the EGR cooler.
• Use the appropriate tools to unbolt these components and set them aside.

By clearing the area around the EGR system, you’ll have easier access to the EGR cooler and related components. This preparation is crucial for the smooth removal of the EGR system.

Removing the EGR Cooler

Now, you’re ready to remove the EGR cooler. This step requires careful handling to avoid damaging other engine components.

Unbolt the EGR Cooler:

• Identify the bolts securing the EGR cooler. Typically, there are six bolts in total: three on each side.
• Use the appropriate socket to remove these bolts. Be cautious as some bolts might be difficult to reach.

Handle Stubborn Bolts:

• If you encounter stubborn bolts, apply penetrating fluid and allow it to sit for a few minutes.
• Use a Sawzall if necessary to cut any obstructing brackets. Ensure you don’t damage surrounding components.

Remove the EGR Cooler:

• Once all bolts are removed, gently wiggle the EGR cooler to break it free from the dowels holding it in place.
• Carefully pull the EGR cooler forward and out of the engine bay. Be mindful of the injector wiring harness and other delicate components.

Successfully removing the EGR cooler is a significant milestone in the EGR delete process. This step paves the way for installing the new components.

Ready to proceed? Let’s move on to installing the EGR delete kit in the next section.

6. Installing the EGR Delete Kit

Installing the Blocker Plates

Now that the EGR cooler is removed, it’s time to install the blocker plates. These plates are essential for sealing off the ports where the EGR components were removed.

Prepare the Blocker Plates:

• Lay out the blocker plates included in your SPELAB EGR Delete Kit.
• Ensure you have the factory gaskets ready to reuse for proper sealing.

Install the Blocker Plates:

Position the first blocker plate where the EGR cooler was removed.

Reuse the factory gasket and secure the plate with the provided bolts. Ensure the bolts are threaded all the way to avoid any leaks.

Repeat the process for the second blocker plate on the exhaust side. Again, ensure the gasket is properly seated and the bolts are securely tightened.

Check for Proper Fit:

Double-check that both blocker plates are correctly installed and there are no gaps or misalignments.

Tighten all bolts to the specified torque to ensure a secure fit and prevent any leaks.

Installing the blocker plates is a critical step in the EGR delete process. Proper installation ensures that your engine runs smoothly without any leaks or performance issues.

Reassembly and Final Checks

With the blocker plates installed, it’s time to reassemble the engine components and perform final checks.

Reinstall the Air Intake System:

Reattach the air intake pipe and secure it with the clamp.

Reinstall the air intake box and reconnect the mass airflow sensor.

Reconnect Electrical Components:

Reconnect all wiring harnesses and sensors that were unplugged earlier.

Ensure that each connection is secure and properly seated.

Add Coolant:

Refill the coolant reservoir and radiators with the appropriate type and amount of coolant.

Replace the caps on the coolant reservoir and radiators.

Reconnect Battery Terminals:

Reconnect the negative battery terminals to restore power to the vehicle.

Perform Final Checks:

• Double-check all connections, clamps, and bolts to ensure everything is secure.
• Look for any signs of leaks or loose components.

By carefully reassembling the engine components and performing final checks, you can ensure that your 6.7L Powerstroke is ready for testing and troubleshooting.

Ready to test your installation? Continue to the next section to learn about testing and troubleshooting your EGR delete.

7. Post-Installation

Testing and Troubleshooting

After completing the installation of the EGR delete kit on your 6.7L Powerstroke, it’s crucial to test the setup and address any potential issues. Follow these steps to ensure everything is working correctly.

Initial Startup Procedures:

1. Turn the ignition key to the "on" position without starting the engine to allow the system to pressurize and check for any immediate issues.
2. Start the engine and let it idle. Listen for any unusual noises and watch for warning lights on the dashboard.

Check for Leaks:

1. Inspect all connections, hoses, and the newly installed blocker plates for any signs of coolant or exhaust leaks.
2. Pay close attention to the areas around the blocker plates and the reconnected coolant lines.

Conduct a Road Test:

1. Take the vehicle for a short drive to ensure everything is functioning properly.
2. Monitor the boost levels and engine performance. If you hear any screeching noises, it might indicate that the blocker plates are not sealed properly, allowing boost pressure to escape.

Address Common Issues:

1. If you encounter any leaks, re-tighten the bolts and clamps around the affected areas.
2. If the engine is not performing as expected, double-check the installation of the blocker plates and ensure all connections are secure.

Recommended Tuning and Adjustments

For optimal performance after installing the EGR delete kit, tuning your 6.7L Powerstroke is highly recommended. Proper tuning will help maximize horsepower, improve fuel efficiency, and ensure the engine runs smoothly.

Select a Tuning Solution:

1. Consider using a truck tuner solution recommended by SPELAB, such as Easy Link with CCS Tunes, to calibrate your engine for the new setup.
2. Ensure the tuner is compatible with the 6.7L Powerstroke and supports EGR delete configurations.

Install the Tuner:

1. Follow the manufacturer’s instructions to install and configure the tuner on your vehicle.
2. Perform any necessary updates or adjustments to match the EGR delete setup.

Test and Monitor Performance:

1. After tuning, take the vehicle for another test drive to ensure everything is optimized.
2. Monitor the engine's performance, fuel efficiency, and any changes in boost levels.

By properly tuning your engine after the EGR delete, you can achieve the best possible performance and longevity for your 6.7L Powerstroke.

Conclusion

Summary and Final Thoughts

Removing the EGR system from your 6.7L Powerstroke and installing the SPELAB EGR Delete Kit can significantly enhance your truck's performance. Here’s a quick recap of the process:

1. Preparation: Gather the necessary tools and components, and prepare your vehicle by disconnecting the battery and draining the coolant.
2. Component Removal: Remove the air intake system and EGR cooler, making space for the new components.
3. Installation: Install the blocker plates and reassemble the engine components.
4. Testing: Conduct thorough tests and make any necessary adjustments to ensure everything is working correctly.
5. Tuning: Optimize your engine’s performance with a suitable tuning solution.

By following these steps, you can successfully complete the EGR delete process and enjoy improved performance from your 6.7L Powerstroke.

For any questions or further assistance, feel free to reach out to us at service@spelabautoparts.com.

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Additional Resources

Useful Links and References

• Recommended Parts and Tools: Visit SPELAB’s website for high-quality EGR delete kits and other performance parts.
• Contact Information: For any inquiries, email us at service@spelabautoparts.com.

FAQs

Q1: Is the EGR delete worth it on a 6.7 Powerstroke?
A1: Yes, performing an EGR delete on a 6.7 Powerstroke can significantly improve engine performance by increasing airflow and reducing soot buildup. However, it is intended for off-road and race use only and may not be legal for on-road use in all areas.

Q2: Is EGR delete good for diesel?
A2: An EGR delete can be beneficial for diesel engines by enhancing performance, improving fuel efficiency, and reducing maintenance issues caused by soot buildup. However, it is important to consider the legal implications and ensure it is used for off-road or race purposes.

Q3: What is the best delete kit for 6.7 Powerstroke?
A3: The SPELAB EGR Delete Kit is highly recommended for its quality components and ease of installation. It includes all necessary parts, such as blocker plates, gaskets, and bolts, ensuring a comprehensive solution for your 6.7 Powerstroke.

Q4: Can you just do an EGR delete?
A4: Yes, you can perform an EGR delete, but it is important to also consider other modifications such as removing the stock exhaust and installing delete pipes or an aftermarket exhaust. Proper tuning is also necessary to ensure optimal engine performance and to prevent any issues.

Q5: Will an EGR delete cause my check engine light to come on?
A5: Yes, removing the EGR system will likely trigger the check engine light. To address this, you will need to use a tuning solution to recalibrate the engine’s computer to recognize the EGR delete and prevent the light from coming on.

Q6: Does EGR delete improve fuel mileage?
A6: An EGR delete can improve fuel mileage by enhancing airflow and reducing the engine’s workload. However, results may vary depending on driving conditions and other modifications made to the vehicle.

Q7: Is EGR delete legal?
A7: EGR delete is generally not legal for on-road use as it bypasses emissions control systems. It is intended for off-road or race use only. Always check local regulations before performing an EGR delete.

Q8: How long does it take to install an EGR delete kit?
A8: Installation time can vary based on experience and familiarity with the process. On average, it can take between 4 to 6 hours to complete the EGR delete installation, including removal of the old components and installation of the new kit.

Q9: What are the risks of doing an EGR delete?
A9: While an EGR delete can enhance performance, it can also void warranties and lead to legal issues if used on-road. Additionally, improper installation or tuning can cause engine damage or decreased performance.

Q10: Do I need to tune my truck after an EGR delete?
A10: Yes, tuning is essential after an EGR delete to ensure the engine runs correctly without the EGR system. Proper tuning can optimize performance, improve fuel efficiency, and prevent error codes or check engine lights.