got a cust truck in that had the turbo stuck.freed it up and tested the system and it passed.cust picked it up and drove about 20 miles and returned with a p0401.he had a stuck egr valve and i replaced it.it passed the engine running test and all was well.the cust returned with it after a half a day.same code.i pulled the vale and started the truck with the valve out and it stayed running.usually the truck will start then die and be hard to restart after the valve is pulled.anyone ever ran across a egr cooler stopped up to where it would pass the engine running test but still turn thee check engine light on after a 20-50 mile trip.any ideas.

 

Did you also replace the oil cooler? I thought Ford REQUIRED that if you need to replace the EGR cooler, you also should (NEED) to replace the oil cooler?

 

havnt done anything yet.the egr cooler is stopped up with soot on the exhaust side.its a truck that gets started up and drove over to the other side of the farm.and yes,if i install a egr cooler it gets a oil cooler also.not fighting a coolant leak justa lack of egr flow.

 

Isn't this cause and effect right there? EGR cooler isn't flowing exhaust into the intake, so no flow through the EGR valve.

How did you determine that the EGR cooler is clogged with soot?

 

I have seen a few rather packed up. the only think you can do at this point is remove and inspect the cooler. if found pluged then you would need to replace it. how long has the guy owned the truck? maybe its blocked off at the rear and the guy does not know it.
have you check iat1 vs iat2 with egr commanded open? whae you check ebp map and baro?

 

ive hade the rear up pipe off and inspected for a block plate.he,s owned it sense new.its up on the 5 yrs warranty and its been in the dealership 6 times to have the turbo cleaned.it ended up at my shop for another turbo cleaning.the unison ring was frozen to the turbo.he has been told by the dealership and me that he needs to blow the cobwebs out of it instead of leting it sit.told him thats the worst thing you can do on these trucks.ebp,map and baro are near same at koeo

 

took the up tube off the pass. side and removed the valve.i poured b-12 into the cooler port and check to see if it would come out of the rear of the cooler.just barley came out.

 

Ugh. If you remove the cooler, can it be hot-tanked to clean it?

 

a stuck turbo will casue a p0401 keep that in in mind.
hot tanking a egr cooler is ill advised. the solder that holds it together may not like that. ymmv

 

i can actuate the vgt solinoid and the mgp pid changes with the commands.ill probably go witha bullitproof egr cooler when i do the job.what do you think

 

commanding the vgt and watching mgp is only telling you the turbo will do something. it does not tell you if its sticking at random time. also note you should be commanding egrdc# as well to both 0% and 100% to correctly test a turbo while sitting in your stall.
what happens to iat1 vs iat when you command egrvp?
what is ficm voltage doing?
whats ebpa doing koeo, whats epba doing at 3k rpm?
whats min and max egrvp? whats total egrvp movement?
do you have a smoke machine?
is the o-ring missing on the pcv tube?
whats fuel pressure?
so many things casue a lack of egr flow.....
above is just a sample of questions to look at.