6.0L Power Stroke VGT Solenoid Replacement

6.0L Power Stroke VGT Solenoid Replacement & Diagnostics Procedures

The VGT solenoid ultimately controls the position of the vanes in the variable geometry turbine housing. Excessive turbocharger lag and overall poor turbocharger performance are typically signs that the VGT system is not functioning properly. A failed solenoid defaults to the open position, making it difficult to build boost. However, it is just as likely (and more common) for the unison ring and vanes in the variable geometry turbine housing to become caked with exhaust grime and fail to move to the commanded position.

Applicable Model Years: 2003 - 2007 6.0L Power Stroke
Garrett GT3782VA VGT solenoid: Garrett 792593-0001
High Temperature Nickel Anti-seize: Motorcraft XL-2

To test a VGT solenoid, measure the resistance across the VGT solenoid coil with a digital multimeter (remove the connector to expose two male pins). The resistance across the solenoid coil should be between 3.42 & 4.18 Ω when engine oil temperature (EOT) is at 73° F. If the resistance reading is out of spec, the solenoid needs to be replaced. Keep in mind that it is much more common to experience stuck/sticking VGT components than it is a faulty VGT solenoid, both of which will hinder turbocharger performance and possibly throw turbocharger related DTCs.

Click any thumbnail to view high resolution fullsize image w/ addition details (where applicable)

VGT solenoid location

• Disconnect both negative battery cables.

• The VGT solenoid protrudes from the bearing housing (center section) of the turbocharger. Locate and remove the VGT solenoid electrical connector.

Retainer bolt location

• The VGT solenoid is held in place by a bracket that is secured with a single retaining bolt - remove the bracket bolt with an 8 mm, 12 point socket.

• Pull the solenoid straight outwards while twisting side-to-side as permitted - a reasonable amount of force is required to unseat the series of o-rings on the solenoid valve. Keep the solenoid orientation parallel to its bore, i.e. do not rock it against the bore in the bearing housing.

• Have a clean rag handy in order to catch the solenoid, which will be covered in motor oil.

Coat new solenoid in motor oil, lubricate o-rings

• Soak the valve and o-rings of the new VGT solenoid in fresh 15W-40 motor oil for several minutes.

• The replacement solenoid includes a new bracket and retaining bolt, so do not reuse the old hardware.

New solenoid installed in turbocharger

• Make sure the o-rings on the solenoid valve are well lubricated, then install the solenoid in reverse order by pushing it into the bore in the bearing housing until it is seated. The solenoid will have a tendency to push out slightly until the bracket is installed.

• Install the solenoid bracket, lightly coating the retaining bolt with high temperature anti-seize to permit future removal. Torque the retaining bolt to 18 lb-ft.

• Clean the electrical connector using a plastic safe electrical connector/contact cleaner, then reinstall the connector. Do not forget to snap the connector retaining clip into place.