If you're tired of dealing with carbon buildup and sensor issues, installing a 2020 6.7 powerstroke egr delete kit might be the smartest move you make for your truck's longevity. It's no secret that Ford's 6.7L engine is a powerhouse, but the emissions gear bolted onto it can sometimes feel like a leash. Between the clogged valves and the constant recirculating of hot, dirty air back into your intake, it's a wonder these engines breathe at all.
Most of us bought these trucks to work. Whether you're hauling a massive fifth-wheel trailer or using it for a daily commute that involves heavy towing, you want reliability. The EGR (Exhaust Gas Recirculation) system is often the first thing to cause a headache once the miles start piling up. It's designed to lower NOx emissions by shoving spent exhaust gases back into the combustion chamber, but in the real world, that just leads to a mess of soot and oily residue.
Why the EGR System is Such a Pain
The fundamental problem with the factory setup is that engines like clean, cool air. By design, the EGR system takes hot exhaust and mixes it with the fresh air coming in from your turbo. This lowers the oxygen content and keeps the combustion temperatures down, which is great for meeting federal standards, but it's pretty rough on the internal components.
Over time, that soot starts to cake onto the intake manifold and the EGR valve itself. It's like trying to run a marathon while breathing through a dirty sock. Eventually, you get a "check engine" light, your fuel economy drops, and you might even end up in limp mode at the worst possible time. A 2020 6.7 powerstroke egr delete kit solves this by physically removing those components and blocking off the ports, ensuring only fresh, clean air enters your cylinders.
What You Get in a Standard Kit
When you finally decide to pull the trigger and order a kit, you'll notice they usually come with a few specific parts. You aren't just getting one single piece of metal. Most kits include high-quality block-off plates, which are usually made from thick aluminum or steel to withstand the heat and pressure. You'll also get the necessary gaskets and hardware to make sure everything seals up tight.
Another big part of the kit is the coolant reroute. Since the EGR cooler is usually integrated into the cooling system, you can't just rip it out and leave the hoses dangling. The kit will provide a way to bypass that cooler so your engine's coolant flows properly without leaking. It's a bit of a project to get it all installed, but once those bulky coolers are out of the way, your engine bay looks way cleaner, and you actually have room to work on other things.
The Necessity of Tuning
One thing you can't overlook is that you can't just slap a 2020 6.7 powerstroke egr delete kit on your truck and call it a day. These trucks are basically rolling computers. If you remove the EGR hardware without telling the truck's ECU (Engine Control Unit) what you did, it's going to freak out. It will throw codes, scream at you with warnings, and likely won't even run right.
You need a "delete-capable" tuner to go along with the hardware. This software update tells the truck to stop looking for the EGR sensors and adjusts the engine parameters to account for the lack of recirculated gas. This is where you often see the biggest jump in performance. When you combine the physical delete with a solid tune, the truck wakes up. The throttle response is crisper, the turbo spools faster, and you'll usually notice a decent bump in miles per gallon because the engine isn't fighting itself anymore.
Is It a Difficult DIY Project?
If you're comfortable with a wrench and have a Saturday afternoon free, you can probably handle this yourself. However, it isn't exactly a "beginner" job. Ford didn't exactly make the EGR cooler easy to reach on the 2020 models. You're going to be reaching over the engine, dealing with tight spaces, and potentially fighting some stubborn bolts that have been heat-cycled thousands of times.
It's always a good idea to have some liquid wrench or penetrating oil on hand before you start. Taking your time is key. If you strip a bolt or nick a coolant line, a simple afternoon job can turn into a multi-day nightmare. But for most guys who do their own oil changes and basic maintenance, it's a manageable hurdle. Just make sure you have a good set of sockets and maybe a buddy to help you lift the heavier components out of the engine bay.
The Performance and Reliability Gains
Aside from just avoiding repairs, the main reason people look for a 2020 6.7 powerstroke egr delete kit is the long-term health of the motor. When you stop pumping soot into your intake, your oil stays cleaner for longer. If you've ever looked at your oil right after a change on a stock diesel, it turns black almost instantly. That's the soot. With the EGR gone, you'll notice the oil stays looking "new" for much longer, which means less wear on your bearings and internal parts.
Then there's the heat factor. EGR coolers are notorious for leaking. When they fail internally, they can actually leak coolant into your intake, which is a recipe for a hydrolocked engine—and that's a bill nobody wants to pay. By removing the cooler entirely, you eliminate that risk 100%. Your engine will also run slightly cooler overall because you aren't circulating 1000-degree exhaust gas through a heat exchanger attached to your cooling system.
Thinking About the Legal Side
It's worth a quick mention that these kits are generally sold for "off-road use only." Depending on where you live, you might have to deal with emissions testing or inspections. If you're in a state with strict smog checks, a full delete might make it hard to pass your yearly registration. Most guys who live in areas without those restrictions don't worry about it too much, but it's something you should at least be aware of before you start tearing parts off your $70,000 truck.
Wrapping Things Up
At the end of the day, installing a 2020 6.7 powerstroke egr delete kit is about taking control of your truck's performance. You're essentially undoing a compromise that the factory had to make. While the emissions systems have gotten better over the years, they still add a layer of complexity and a potential for failure that many owners just don't want to deal with.
If you plan on keeping your truck for the next ten years or 300,000 miles, getting rid of the soot-maker is one of the best "preventative maintenance" steps you can take. You'll get a truck that runs better, stays cleaner, and sounds a whole lot meaner when you step on the gas. It's an investment in the truck's future, and for most 6.7 owners, the peace of mind alone is worth the price of the kit. Just make sure you grab a high-quality kit and a reputable tuner, and you'll be set for the long haul.