6.0L Power Stroke EGR Valve Replacement

Power Stroke EGR Service Tutorial


6.0L Power Stroke owners are all too familiar with that pesky, problematic EGR valve. The EGR valve is an emissions component that meters the recirculation of exhaust gases into the intake. Without getting too technical, recirculating exhaust gases reduces the amount of oxygen available during combustion and reduces NOx emissions. Over time, the EGR valve can build it with soot and stop functioning properly. Depending on the position the valve gets stuck in, a variety of symptons can emerge including turbo overboosting, reduced performance/fuel economy, and engine overheating. While we chose to service the EGR on a 6.0L powered Ford, servicing the EGR is important for any EGR equipped diesel. The 6.0L Power Stroke and 6.7L Cummins engines seem to require the most attention in this department.


The truck featured in this tutorial has not received an EGR service in over 100,000 miles. To make matters worse, the truck has racked up 175,000 miles on the factory injectors, and the truck is starting to smoke a bit under load. We expected the valve to be caked with gobs of soot, but were pleasantly surprised to find that the build up was much less than expected from a truck with this many miles.


EGR Removal Tool

There's a variety of methods and tools that can be used to remove an EGR valve. Heavy soot deposits typically lodge the valve into the intake, so don't expect to be able to muscle it out on your own. This tool we used is simple to fabricate and you'll find a variety of uses for it. Simply heat and bend the tip of an old screwdriver to roughly a 90 degree angle. With this simple solution, you can literally replace the EGR valve in under 15 minutes.


• Begin by locating the EGR valve. On the 6.0L Power Stroke, the EGR valve bolts to the intake manifold directly behind the air horn. If you've got sausage fingers, it's going to be a tight fit.
• Start by removing the wiring harness that plugs into the top of the EGR valve. A small flathead screwdriver can be used to unlock the clasp on the harness.
• Using a socket and extension, remove the 2 5/16" bolts that secure the EGR valve. If you have sausage fingers, use a long pair of needle nose pliers to recover the bolts once they are unthreaded.
• Grabbing the top of the EGR valve, you should be able to pull it to one side just enough to slide your tool underneath the lip. Pry it slightly on one side, then the other side, and repeat until it can be removed.
• With the valve removed, clean the EGR port with a rag and a shop vac. The goal is to remove the build up and remove it from the port.
• Reinstall the EGR valve in reverse order, using a small amount of anti-seize on the bolts. Since the intake manifold is cast aluminum, do not overtighten the bolts as you will risk stripping the threads.
• If the original valve is still in decent shape, you can clean it, replace the o-rings, and reuse it when needed.


6.0L Power Stroke Replacement Pictures

(click to view fullsize):


Our simple EGR valve removal tool fabricated from a spare screwdriver.

The EGR valve is located behind the air horn, in front of the oil filter housing.

Unclasp and remove the plug on top of the EGR valve.

Wrestle your tool underneath the lip of the valve and pry up to remove it.

EGR port after removing the valve.

EGR port after cleaning & removing debri with a shop vac.

Comparison of the old and new EGR valves.

Soot build up may be impeding the function of the valve, but we've seen MUCH worse.

Installation is opposite removal. Don't forget the harness and some anti-seize on the bolts.



Related Topics:

6.0L Fuel Filter Replacement Power Stroke Maintenance Schedule
6.0L Power Stroke Oil Change Diesel Maintenance Home