6.7 Powerstroke EGR Delete Install Guide (2011–2025 Models)

While factory-installed exhaust gas recirculation (EGR) systems are designed to reduce emissions, they often lead to carbon buildup, power loss, and reduced fuel efficiency over time. Therefore, many car owners choose to remove the EGR system to unleash the engine's full power. This step-by-step guide will show you how to delete EGR on 6.7 Powerstroke engine using Vigor Diesel's reliable EGR delete kit; even DIY enthusiasts can easily do it.

⚠️Important Legal Notice: This product is for off-road racing use only and must not be driven on public streets, highways, or expressways. Please ensure compliance with local laws before installing this product.

Required Tools and Checklist

Required Tools

• Metric socket set (including 8mm)
• Allen/Hex key set
• Hose clamp pliers
• Coolant drain pan
• WD-40 or penetrating lubricant
• Zip ties
• Safety goggles/gloves

Vigor Diesel EGR Delete Kit Components

• 1*Coolant Hose
• 2*Hose Clamp
• 1*Hose Sleeve
• 1*Stator, 6*Zip-Tie
• 2*Block Off Plate
• 1*Silvery Gasket
• 1*Black Gasket
• 1*Copper Column
• 5*Locking Nut
• 3*Long Silvery Screw
• 1*Short Silvery Screw
• 2*Short Black Screw

Important Notes & Installation Tips

Before you start 6.7 Powerstroke EGR delete install​, please note the following:

• Allow the engine to cool completely (avoid overheating).
• Park the vehicle on a level surface, engage the handbrake, and use a ramp to access the undercarriage.
• For older vehicles, spray rust remover on the bolts 10 minutes before disassembly to prevent stripping – this is a common issue we encounter in customer feedback.
• Mark the bolts/parts during disassembly; retain original hardware/shims for reuse.
• Wear safety goggles when working under the vehicle.
• ECU tuning must be completed before removing any emissions-related components.

Step-by-Step Installation Guide

Follow these steps to successfully install the 6.7 Powerstroke EGR Delete Kit.

Step 1: Safety Preparation and Coolant Drain

Before starting any work, ensure the vehicle is completely cooled. Wear safety glasses and work in a well-ventilated area.

Disconnect the negative terminals of both batteries to eliminate electrical hazards. Next, locate the radiator drain hole on the driver's side and place a bucket underneath it to drain all coolant.

Step 2: Disconnect the Intake System and Related Coolant Lines

The goal of this stage is to remove components obstructing EGR system servicing.

First, loosen the red clip to disconnect the MAF sensor. Use an 8mm wrench to remove the bolts securing the intake box and reservoir, then lift the entire assembly off its rubber mounts. Loosen the two clamps on the intake coupling. Next, pull up on the remaining intake tube to remove it, freeing the three coolant lines attached to its clips. Finally, disconnect the clips and brackets that hold the two larger coolant lines going directly to the EGR cooler, and remove these lines completely.

Step 3: Disconnect Coolant, Electrical, and Vacuum Connections

First, remove the two hose clamps from the small coolant “T” connector, disconnect the hose, and then install the included straight-through barbed connector. Connect the included coolant hose from the expansion tank (overflow tank) to the opening below the radiator on the passenger side.

Next, disconnect all EGR-related connections, including the EGR temperature sensor, the PCM harness on the passenger-side firewall, the harness (three connectors) on top of the EGR cooler, the vacuum hose on the EGR system, and the butterfly valve connector near the fan shroud. Properly store all disconnected wires and hoses away from heat sources and moving parts.

Step 4: Remove the EGR Pipes and Cooler Assembly

First, remove the short EGR hose (4 bolts), then remove the long EGR hose (5 bolts). Keep all original bolts and washers for reuse, and cover the intake manifold opening to prevent debris from entering.

Next, remove the heat shield clips, wiring harness bolts, and the 7 bolts securing the EGR cooler. Also remove the nuts securing the rigid pressure hoses at the rear of the cooler. Carefully pull the EGR cooler forward out of the engine compartment and disconnect any remaining clips or wiring harnesses.

Step 5: Install the Exhaust Plug and Rewire

Install the included exhaust plug plate using the previously removed original factory gaskets and bolts. Install the coolant plug plate using the provided Allen bolts.

Reconnect the PCM harness and quick-connect coolant lines. Secure the unused EGR harness and vacuum lines to the PCM harness using cable ties. Install the intake plug plate using the included O-ring; no original factory gaskets are required. Finally, install the included bracket to secure the rigid pressure lines at the rear passenger-side air intake.

Step 6: Reinstall Intake Components and Refill Coolant

Reinstall all intake components in the reverse order of disassembly and add coolant to the original factory specifications. Finally, start the engine and allow it to reach operating temperature while checking for coolant leaks.

Special Steps: Coolant Reroute for 2015–2016 6.7 Powerstroke

The 2015–2016 Ford 6.7 Powerstroke requires coolant rewiring: Install the supplied mounting bracket first, followed by the coolant re-route hose. Finally, reconnect the 90-degree hose to the firewall fitting.

Note: Vigor Diesel's upgrade kit includes a baffle plate to improve coolant circulation, reducing engine temperature by 10.8°F compared to the standard kit.

Post-Installation: Testing and Tuning Tips

Initial Inspection: Before starting, double-check all hose connections for tightness, bolts for tightness, and wiring harnesses for being stored away from high-temperature or moving parts.

Leak Test: Start the engine and let it idle until it reaches operating temperature. Carefully inspect all modified coolant connections, baffles, and original hoses for leaks.

Coolant Level: After the engine is warm (thermostat open, large loop), check and top up the coolant in the overflow reservoir to the standard mark.

Road Test (Off-Road Only): Conduct the test in a safe, closed area to check power response and turbocharger operation.

Final ECU calibration: Verify the calibration status using the appropriate ECU tuning software and clear any residual fault codes associated with the removal of the EGR component.

FAQs about 6.7 Powerstroke EGR Delete Installation

Conclusion

Removing the EGR system from the 2011-2025 Ford 6.7L Powerstroke engine using Vigor Diesel's EGR Removal Kit is an effective way to improve performance and reliability, especially for off-road enthusiasts. Following this guide will help you avoid common mistakes and enjoy the numerous benefits of reduced carbon buildup and improved engine efficiency.

Ready to upgrade your Powerstroke engine? Visit Vigor Diesel today to order your EGR Delete Kit. For support, please contact [email protected].