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EGR Delete Trouble Codes Explained: Causes & Fixes for Your Diesel Truck
April 21, 2025

EGR Delete Trouble Codes Explained: Causes & Fixes for Your Diesel Truck

If you've installed an EGR delete kit on your diesel truck (like a Duramax, Powerstroke, or Cummins), you've probably seen check engine lights and error codes pop up. This happens because modern trucks rely on the Exhaust Gas Recirculation (EGR) system for emissions control—and removing it confuses the engine's computer (ECU).

In this guide, we’ll cover: 

Why EGR deletes trigger trouble codes
The most common EGRrelated error codes
How to fix them (without reinstalling the EGR system!)
Best tuners and bypass solutions

Why Does an EGR Delete Cause Check Engine Lights? 

When you delete the EGR system, the ECU expects certain sensor readings that suddenly disappear. This triggers Diagnostic Trouble Codes (DTCs), including:
  1. P0401 – Insufficient EGR Flow
  2. P0404 – EGR Circuit Range/Performance
  3. P0405 – EGR Sensor "A" Circuit Low
  4. P0406 – EGR Sensor "A" Circuit High

These codes appear because: 

The ECU monitors EGR valve position, flow rate, and temperature
Without the EGR system, sensors send zero data
The truck’s software thinks there’s a malfunction

How to Fix EGR Delete Codes (3 Proven Methods) 

1. Use a Tuning Tool to Disable EGR Monitoring

The best longterm solution is reprogramming the ECU with a custom tune that:
Deletes EGRrelated DTCs
Adjusts fuel mapping for better performance
revents limp mode
Recommended Tuners:
EFI Live (best for Duramax)
HP Tuners (works with Powerstroke & Cummins)
Banks iDash + Derringer (plugandplay option)

2. Install an EGR Simulator/Emulator 

If you don’t want to tune, an EGR simulator tricks the ECU into thinking the EGR is still active.
Pros: No tuning required, reversible
Cons: Doesn’t improve performance like a tune

3. Manually Clear Codes (Temporary Fix) 

If you just need to pass an inspection, you can:
1. Use an OBD2 scanner to clear codes
2. Drive until monitors reset (may take 50100 miles)
3. Avoid codes returning by keeping the EGR cooler hooked up (if possible)
(Note: Codes will likely return unless you tune or simulate!)

Will an EGR Delete Hurt My Engine? 

No—if done correctly. In fact, deleting the EGR can:
Reduce carbon buildup in the intake
Lower engine temps (better for towing)
Improve throttle response
But without proper tuning, you risk: 
Reduced fuel efficiency (ECU runs in "safe mode")
Failed emissions tests (in some states)
Voided warranty (if detected)

Legal Note: Is an EGR Delete Street Legal? 

In the U.S., removing emissions equipment violates EPA laws. Fines can exceed $10,000 for individuals and shops.
Alternatives for StreetLegal Trucks:
EGR cleaning service (removes carbon without deletion)
Highflow EGR coolers (reduces clogging)
Mild performance tunes (keeps EGR functional)

Final Verdict: Best Way to Fix EGR Delete Codes 

For offroad/competition trucks: Full delete + custom tune (best performance)
For daily drivers: EGR emulator or cleaning (keeps it legal)
Need help choosing the right solution? Check out our EGR delete kits, tuners to keep your diesel running strong—without the check engine lights!


Next article How to Clean EGR Valve on 6.6L Duramax: Quick Easy DIY Guide

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