Symptoms Of A Bad 6.0 Powerstroke EGR Valve (Explained)

6.0L Power Stroke EGR (exhaust gas recirculation) valve is an emission device that controls the number of exhaust gases that are reintroduced into the engine, essentially diluting the intake charge to reduce NOx emissions. But a failed 6.0 powerstroke EGR valve can contribute to reliability.

The users who have experienced 6.0 powerstroke EGR valve failure they could have prevented the problem if they were aware of the initial sign and symptoms to get a hint. 

Therefore, in this very article, let’s learn how to detect when your EGR valve needs immediate attention.

What Is The Sign Of A Faulty 6.0 Powerstroke EGR valve? The most common and obvious signs of 6.0 powerstroke EGR valve failure are soot buildup, a loss of power, excessive carbon buildup, and more.

6.0 Powerstroke EGR Valve Failure Symptoms:

There are other significant symptoms by which you can easily identify when your EGR valve needs proper inspection and repairing or replacement. 

So, let’s learn more about those symptoms and how to detect 6.0 powerstroke egr valve failure –

1. Issues with Engine Performance

If you face issues with your engine performance, this can be a symptom of a problem with the EGR valve. A malfunctioning or faulty EGR valve can mess with your vehicle’s air-fuel ratio. And it can cause problems like reduction in power, fuel efficiency, and acceleration.

2. Rough Idle

Rough idle is one the most common symptoms to identify a bad EGR valve. EGR valves often get stuck in an open position when they malfunction. And by getting stuck, it can lead to exhaust gas circulation, which eventually causes rough idle. 

To identify the problem, first put the vehicle in a parked position. Then look for a plunger shaft and, if possible, check for the valve positioning. Try to do that physically. There will be error codes in cases where the valve is stuck in an open position. You would just have to remove the plug and fill the empty spaces with carbon cleaner.

In case of EGR stuck closed position, first, you would have to check for error codes P014 and P1406 OBD ECU scan tool. Then if you hear any knocking sound from the engine, know that the valve has already been shut down. 

3. Check Engine Light

If your vehicle’s EGR valve has an issue and the computer detects that, it will set off the Check Engine Light on the dashboard to notify the issue. The Check Engine Light can also get set off for other issues with the engine. 

But as the EGR valve is directly connected to the engine, bad valve setting the light on is often the case. Thus, it’s one of the important symptoms to look at.

4. Smell of Fuel

When the EGR valve does not function properly, the engine takes up more fuel than it is supposed to. 

For that, the hydrocarbon starts to leave the tailpipe. And this action causes fuel odor to increase.

Often the odor is irritating, and you can smell it from inside the vehicle, making it one of the symptoms of a bad EGR valve.

5. Emissions Test

If your vehicle fails the emission test that is taken every six months, this can be because of a bad EGR valve. And if you can find other symptoms along with failing the test, it’s almost surely a problem of the EGR valve. 

A smog test is really an effective way to detect a clogged EGR. If your EGR valve is clogged, it can no longer burn harmful emissions inside the combustion chamber and fails to emit NOx out of the exhaust pipe. And that will tell you if the EGR valve is in a good situation or bad.  

6. Knocking Sound

Another symptom is the knocking sound of the engine. If your EGR valve is stuck in a closed position, the temperature inside the combustion chamber will be too high. And this ultimately leads to fuel igniting too early when the engine is at low RPM, causing the knocking sound from the engine. 

These are the most commonly identified symptoms that indicate the EGR Valve failure condition. So, if you also own one of the 6.0 Powerstroke engines on your vehicle, make sure to keep them in mind.

What to Do When You Detect 6.0 Powerstroke EGR Valve Failure?

Whenever you encounter any symptoms indicating that your egr valve may fail or has any damage, make sure to follow the below instructions in order to fix the problem-

All the problems regarding EGR valves are generally caused by two different reasons and you will see different symptoms for each reason.

The valve either becomes stuck in the open position or in the closed position. So, you need to figure out the problem first to solve it.

You should get yourself an OBD (On-Board Diagnostics Device) and plug it into the vehicle to check the errors. The device will show different error codes when diagnosed to let you know about the problem.

EGR Valve Stuck in Open

Error code P0402 will be shown in this case. You’ll have to remove the plug and fill the empty space with a carbon cleaner if it happens.

EGR Valve stuck in close

Code P0401 warns when the EGR valve is stuck in close. However, there’s not an easy solution to this problem. First, you need to figure out the exact source of the problem and act according to it. In most cases, you’ll need to remove the valve, and a valve removing kit will come in handy.

See a mechanic, and it can cost $150 to $750 to solve the problem.

Clogged EGR Valve

Error code P0401 can also be shown If the valve is blocked. Actually, this code refers to insufficient EGR flow. You’ll need to remove the valve and clean it properly with a valve cleaning kit or throttle body cleaner.

While cleaning the valve, put on an acid-resistant pair of gloves and safety glasses. Spray the cleaner onto the carbon deposits and remove the carbon build-up with a pipe cleaning brush.

Wipe off the place with a clean cloth when all the carbon deposits are removed. If you find it hard to clean using the pipe brush, soak it in a cleaning solution for a few minutes before doing the brushing process.

Finally, replace the EGR valve, and it should solve the problem.

Is Replacing A 6.0 Powerstroke EGR Valve Typically Expensive?

First of all, a common question comes to mind – Repair or replacement?

Most of the egr valve-related problems like merely clogged or stuck open or closed due to soot particles can be solved by cleaning them. But you’ll have to remove the valve and replace it for this. 

So first, take the body and eye protection as mentioned earlier. Now start the removal process. You need to remove different electronic parts before removing the valve. 

Carefully remove the rubber vacuum line that is connected to the EGR valve. If you find it broken or damaged, replace it. Otherwise, it can create different engine problems. Now disconnect all the electrical connections. 

Make sure you don’t use any corrosive chemical cleaner near the wiring. Then you’ll have to unbolt the EGR valve from the assembly. If the valve doesn’t come out even after removing nuts and bolts, give a slight tap with a tiny hammer to loosen it. Finally, remove the gasket. Replace it if it’s torn. Now it’s time to clean the valve. 

Follow the above-mentioned process to clean the valve and reinstall it. Reattach the cacxum hose and electrical connections. Now you are ready to go!

For replacement, the estimated cost can reach be between $150 to $500, including both parts and labor. 

The cleaning process can be done by yourself.

This should cost about $15 for the cleaner and between $70 to $490 for the part.

The Verdict

An EGR valve is an essential part of a vehicle’s emission system by recirculating the exhaust back into the engine. A car with a faulty EGR valve could increase a car’s pollution output and cause it to fail inspection. 

Therefore, any slight malfunctioning issue with the EGR valve is real bad news. Still, prevention can help you keep your valve healthy, and those above discussed symptoms will help keep a close eye on your EGR valve to prevent any severe issue.

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