Engine problems after EGR vavle is damaged - Ford Powerstroke Diesel Forum
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Old 10-11-2009, 01:51 PM
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Engine problems after EGR vavle is damaged

me and a friend of mine were cleaning the egr valev in my 04 6.0. we took the valve out cleaned it with carb cleaner and started to put it back in. we got it past the first o-ring but could not get it passed the second. so, in my infinte wisdom, i decided to tap the top, plastic portion of the valve with a 1/4 drive and a hammer. the top of the plastic portion caved in maybe an 1/8 of an inch . by this time the screws could reach the threads so i just tightened them down to finish getting the valve in place. after we had the valve back in place i started the truck. it idles very rough for <10 seconds then quits. i cranked ot twice and the same thing happened. will simply replacing the egr valve fix this? if so how much will it cost me?
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Old 10-17-2009, 10:34 AM

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Yeah replacing the valve could be a start since it sounds like you damaged the plungger I would recommened removing the valve and visually inspecting it, yo might have hit that plungger out of it's base, the lower plate must sit flush to i t's base if not you will experience a lack of power and black smoke on accell. and it may die, you might have also damage wiring I'd replace it just to be on the safe side

The valve will run you for about 200$ at your local ford dealer or you can find them for about 120$ online!
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