EGR Valve Cleaning & Repair

Restore engine performance and reduce emissions with professional EGR service for all diesel platforms.

The Exhaust Gas Recirculation (EGR) valve is one of the most maintenance-intensive components on a modern diesel engine. It recirculates a portion of exhaust gas back into the intake to lower combustion temperatures and reduce NOx emissions. Over time, carbon and soot from the exhaust coat the valve, passages, and cooler — restricting flow, causing the valve to stick, and triggering a cascade of driveability and emissions problems.

$200-$400

Professional Cleaning

vs.

Save 50%+

$400-$900+

Valve Replacement

Our EGR Cleaning Process

Diagnostic Scan

We pull codes and monitor live EGR position, flow rate, and temperature data using factory-level scan tools to confirm the EGR system is the source of the problem.

Removal & Inspection

The EGR valve and related passages are removed and inspected for carbon buildup, stuck pintles, cracked housings, and damaged diaphragms or actuators.

Cleaning & Testing

Carbon deposits are removed using a combination of chemical soak and mechanical cleaning. The valve is bench-tested for proper opening, closing, and sealing before reinstallation.

Reinstall & Verify

After reinstallation we perform an EGR function test, verify proper flow rates, and clear all codes. A test drive confirms normal operation and smooth idle.

Platform-Specific EGR Issues

Ford 6.0L & 6.7L Power Stroke

The 6.0L is notorious for EGR cooler failures that can crack and leak coolant into the exhaust or intake, leading to white smoke and potential engine damage. The 6.7L uses an improved cooler design but still accumulates heavy carbon on the EGR valve, especially with extended idle time. We inspect the cooler every time we service a 6.0L EGR system.

GM 6.6L Duramax

LBZ and LMM Duramax engines are prone to EGR valve sticking from carbon buildup in the cooler passages. The LML introduced a revised EGR system but still benefits from periodic cleaning. L5P models have improved EGR flow management but are not immune to soot accumulation, particularly in stop-and-go driving conditions.

Ram 6.7L Cummins

The Cummins 6.7L EGR valve uses an electronic actuator that can fail independently of carbon fouling. Common symptoms include intermittent fault codes and erratic idle. Carbon buildup in the intake manifold and EGR passages is also a frequent issue, especially on trucks used for towing in hot weather. Regular cleaning prevents cascading failures.

EGR Cooler Inspection & Repair

The EGR cooler uses engine coolant to lower exhaust gas temperature before it re-enters the intake. A cracked or clogged cooler reduces EGR efficiency, can introduce coolant into the combustion chamber, and accelerates valve fouling. We pressure-test the cooler during every EGR service and recommend replacement when internal damage is found.

Intake Manifold Carbon Cleaning

Recirculated exhaust gas deposits carbon throughout the intake manifold and runner passages, restricting airflow and reducing engine efficiency. When we service the EGR valve, we also inspect and clean the intake passages to restore full airflow. This is especially important on high-mileage trucks that have never had an EGR service.

Signs Your EGR Valve Needs Service

Check engine light (P0401, P0402, P0403, P0404, P0405)

Rough or unstable idle, especially when cold

Noticeable loss of power and throttle response

Increased fuel consumption

Failed emissions testing (elevated NOx readings)

Black smoke under acceleration

Engine knocking or pinging (pre-detonation)

Strong exhaust smell in the cabin

EGR Cleaning FAQ

What does the EGR valve do?

The Exhaust Gas Recirculation (EGR) valve redirects a metered amount of exhaust gas back into the intake manifold. This lowers combustion temperatures and reduces nitrogen oxide (NOx) emissions. In diesel engines, the EGR system is a critical part of the emissions control strategy and works alongside the DPF, DOC, and SCR systems.

How much does EGR cleaning cost vs. replacement?

Professional EGR valve cleaning typically costs $200-$400 depending on accessibility and the extent of carbon buildup. Replacement of the EGR valve runs $400-$900+ for parts and labor on most diesel pickups. EGR cooler replacement, when needed, can add $800-$1,500+ due to labor intensity. Cleaning is always worth trying first if the valve is not mechanically damaged.

How often should the EGR valve be cleaned?

There is no universal interval, but most diesel EGR valves benefit from inspection and cleaning every 50,000-80,000 miles, especially in vehicles that do a lot of city driving or idling. Trucks used primarily for highway driving may go 100,000+ miles before significant buildup occurs. If you notice rough idle, loss of power, or a check engine light with EGR codes, have it inspected promptly.

Can a bad EGR valve damage other components?

Yes. A stuck-open EGR valve floods the intake with excess exhaust gas, reducing power and increasing soot production, which accelerates DPF clogging. A stuck-closed EGR raises combustion temperatures, increasing NOx output and stressing the SCR/DEF system. Leaking EGR coolers can introduce coolant into the intake, risking engine damage. Addressing EGR problems early protects the entire emissions system.

What causes the EGR valve to clog?

Carbon buildup from exhaust soot is the primary cause. Diesel exhaust contains particulate matter that gradually coats the EGR valve, passages, and cooler. Short trips, excessive idling, low-quality fuel, overdue oil changes, and high-mileage engines with increased blow-by all accelerate carbon accumulation. The EGR cooler can also develop deposits that restrict flow over time.

Should I delete or disable my EGR?

We do not perform EGR deletes. Removing or disabling the EGR system is a violation of the federal Clean Air Act and can result in significant fines. It also voids your warranty and will cause an automatic emissions test failure. Our approach is to keep your EGR system working properly through professional cleaning and repair so you stay compliant and avoid costly problems down the road.

Serving Willow Springs, Lemont, Burr Ridge, Hodgkins, Countryside, La Grange, Hickory Hills, Justice, Bridgeview, and the greater Chicagoland area.

EGR Problems Slowing You Down?

Call us today to schedule an EGR inspection and cleaning. We service all diesel platforms.

Request Appointment Call (708) 839-1515