Hey everyone, this is my first post.
I own a 1989 F150 with the 4.9l engine.
I ran a koeo self test last night and got a code that my egr valve position/pressure feedback was below minimum.
I had some time to kill so i thought why not pop it off and clean it out and see if that does anything.
Things started to go wrong almost immediately...
First I broke a bolt connecting the valve to the engine inside the threading...
Then i decided i really needed to get it off so i could get that out.
next i'm trying to get the nut attaching the valve to the pipe off and the top part of the valve that has a bolt running through it snapped off.

So now i have an EGR valve that i can't get off all the way and can't put back on all the way.

I really messed up, I've PB blasted the pipe nut but no matter how hard i go at it it won't budge.
I'm waiting for my roommate to get home because i think he has a propane torch somewhere.

Any suggestions for removal including the bolt would be extremely helpful...
Thanks

 

oof, that sucks. Not an easy place to get an easy out to get the broken bolts, or any other tool really.

Is there any space between the valve and the mounting plate it mounts to? Did you get it backed out at all?

I usually weld a handle onto a stripped or broken bolt if there's enough room, but that probably doesn't help since getting a gun in there at the right angle is probably impossible.

Your valve is going to need to be replaced now that it's broken. You should be able to just cut the rest of it to pieces with a cutoff wheel on a grinder, or a multitool, or sawzall, or hacksaw. If you can break apart the valve, it may create enough access to grab the first bolt you broke. You can use aluminum foil as a formable debris/spark shield around the area.

First try the easy out if you can get it on. Otherwise, turn the valve into little bits. Or wait for someone smarter than me to post.

 

So you're having trouble accessing the egr to get the broken bolt out?

Intake plenum gaskets are cheap, just pull the upper intake. Then you can weld a nut to the broken bolt as suggested above.

Don't be afraid to cut the egr tube either....it it were mine I'd be blocking it off anyway. You can delete the egr tube and block off both ends, but the valve needs to stay in tact to prevent a code.

 

Well one bolt from the egr is stuck in the engine body...
I was thinking about plugging it but if I can't reattach the valve would it work?
If I cut the pipe and plug it, then plug the spot the egr valve would be connected to is it fine to leave the egr as is?
Or does it need to be plugged as well?

 

You could technically remote mount the egr, if that's what you're asking, but you'll have to block the intake and exhaust sides of the egr.

"Stuck in engine body, do you mean intake?

 

Yeah, I was thinking I'd be able to get it out but it's really stuck, I filed it flat on the top and bottom so I could get a good grip with vice grips and still not budging...

 

Welding a nut to it is absolute best, it's stuck because of the difference in material over the years. The heat shock alone from tacking a nut to it will work wonders. Pull the upper intake off if you can't access it, it take you no time at all.