Yet another EGR issue ?
Thread Starter
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Senior User
Joined: Mar 2014
Posts: 152
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From: Indianapolis, IN
Replaced MAP sensor - didn't fix problem.
First few WOT runs today, problem present - then finally cleared & won't return until truck sits for awhile. I did notice that EVM varied up to 6 or so during bad runs.
During good runs, I get the following SG-II readouts at Idle & Cruise:
EGR = 0
EGV = 0
EVD = varies
EVM = 0
New fuel filters arrived - will replace & clean HFCM (groping around in the dark)
First few WOT runs today, problem present - then finally cleared & won't return until truck sits for awhile. I did notice that EVM varied up to 6 or so during bad runs.
During good runs, I get the following SG-II readouts at Idle & Cruise:
EGR = 0
EGV = 0
EVD = varies
EVM = 0
New fuel filters arrived - will replace & clean HFCM (groping around in the dark)
Last edited by 11jjonn; Dec 9, 2014 at 11:23 AM. Reason: added info
Postmaster
Joined: Jan 2005
Posts: 4,424
Likes: 12
From: BC Canada
Clean Intake temp, next to MAF sensor in intake tube before turbo, clean MAF inside intake tube, clean Exhaust Back Pressure sensor and clean tube, clean MAP tube on pass side intake, and be sure to clean EGR and go through relearn each time you then test. ie, disconnect batteries with headlights on, wait 20 minutes, reconnect batteries, then cycle ignition on 3 times waiting 30 seconds each time. You will know you did this when your HVAC controls all have to be resent to temperatures properly. NOw, start the truck and let it idle for 10 - 15 minutes before driving and testing. I had this same problem changing EGR and doing this cleaning. Reset and relearn has to be done right to fix this issue. You can tell by changing HVAC to Degrees Celsius, before disconnecting batteries, it will revert to degrees F once the reset is complete. Then you need to let it idle, you may even hear it cycling the EGR when it relearns upon starting.
What is your MAP and BARO readings and Key on Engine Off, are the sensors matching? What is IAT2 and Outdoor Air Temp at cold soak on HVAC, are they matching?
You will perservere and resolve this!
What is your MAP and BARO readings and Key on Engine Off, are the sensors matching? What is IAT2 and Outdoor Air Temp at cold soak on HVAC, are they matching?
You will perservere and resolve this!
Last edited by mhoefer; Dec 9, 2014 at 06:56 PM. Reason: Fat fingers and bad spelling
Thread Starter
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Senior User
Joined: Mar 2014
Posts: 152
Likes: 0
From: Indianapolis, IN
OK, good - more things to check.
Will clean mentioned sensors - accomplish re-learn procedure - pay more attention to sg-II readouts while problem present......
Do not have another egr valve to install - will order when more convinced.
Will clean mentioned sensors - accomplish re-learn procedure - pay more attention to sg-II readouts while problem present......
Do not have another egr valve to install - will order when more convinced.
Thread Starter
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Senior User
Joined: Mar 2014
Posts: 152
Likes: 0
From: Indianapolis, IN
Latest....
Drained Water Separator (no water), flooded chamber with carb cleaner = minor grit.
Primary filter had minor grit, chamber had small area of grit - removed grit, replaced filter.
Secondary filter quite clean, no signs of grit in chamber. Replaced filter.
Cycled KOEO 30 seconds, X3.
Previously, most egr readouts = 0.
Disconnected egr valve connector, sprayed both connections with wd-40, wiped excess, reconnected.
All egr readouts present/normal.
WOT runs:
Initially, hesitation at shift point (3000 rpm) - backed off throttle to allow shift/turbo spoolup.
Remainder of runs (7-8), good power/boost = 20+.
I'm as confused as in the beginning..........
Will see how truck performs tomorrow.
Drained Water Separator (no water), flooded chamber with carb cleaner = minor grit.
Primary filter had minor grit, chamber had small area of grit - removed grit, replaced filter.
Secondary filter quite clean, no signs of grit in chamber. Replaced filter.
Cycled KOEO 30 seconds, X3.
Previously, most egr readouts = 0.
Disconnected egr valve connector, sprayed both connections with wd-40, wiped excess, reconnected.
All egr readouts present/normal.
WOT runs:
Initially, hesitation at shift point (3000 rpm) - backed off throttle to allow shift/turbo spoolup.
Remainder of runs (7-8), good power/boost = 20+.
I'm as confused as in the beginning..........
Will see how truck performs tomorrow.
Thread Starter
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Senior User
Joined: Mar 2014
Posts: 152
Likes: 0
From: Indianapolis, IN
More info (via SG-II) - more questions.
2 pressing issues - EGR & Turbo operation.
Initially, during mild driving (at 190*), EGR Valve Position Measured % closely follows EGR Valve Position Desired % (3-12).
After 5 minutes, Desired continues varying - but Measured goes to 0.
VGT (VGT Duty Cycle %) @ KoEo = 0.
Idle (650rpm) = 62 (Boost = .6)
Cruise (2400rpm) = 44 (Boost = 10 @ 50 mph)
WOT (3600rpm) = 31 -- (Boost max = 20 PSI @ 70-80 mph)
Actions taken so far:
Replaced MAP sensor, checked hose & manifold nipple.
Sprayed MAF sensor with CRC cleaner.
Replaced leaking hot-side turbo cac boot.
Replaced fuel filters, cleaned hfcm chambers.
Removed EGR valve & lightly cleaned (bottom o-ring slightly rubbed)
Need to thoroughly clean it & manifold port - replace gasket/o-rings.
Performed re-learn procedure.
Original issue of PCM seeming to command de-fueling upon WOT still present. It's as if a sensor is telling PCM there's a fault condition - but, no Check Gauge lamp.
Have to do 4-5 WOT runs, backing off accelerator to get rpm past 2900/4.0 Boost. Eventually, rpm to 3200, upshifts, Boost = 10-12.
Advice/suggestions greatly appreciated.
2 pressing issues - EGR & Turbo operation.
Initially, during mild driving (at 190*), EGR Valve Position Measured % closely follows EGR Valve Position Desired % (3-12).
After 5 minutes, Desired continues varying - but Measured goes to 0.
VGT (VGT Duty Cycle %) @ KoEo = 0.
Idle (650rpm) = 62 (Boost = .6)
Cruise (2400rpm) = 44 (Boost = 10 @ 50 mph)
WOT (3600rpm) = 31 -- (Boost max = 20 PSI @ 70-80 mph)
Actions taken so far:
Replaced MAP sensor, checked hose & manifold nipple.
Sprayed MAF sensor with CRC cleaner.
Replaced leaking hot-side turbo cac boot.
Replaced fuel filters, cleaned hfcm chambers.
Removed EGR valve & lightly cleaned (bottom o-ring slightly rubbed)
Need to thoroughly clean it & manifold port - replace gasket/o-rings.
Performed re-learn procedure.
Original issue of PCM seeming to command de-fueling upon WOT still present. It's as if a sensor is telling PCM there's a fault condition - but, no Check Gauge lamp.
Have to do 4-5 WOT runs, backing off accelerator to get rpm past 2900/4.0 Boost. Eventually, rpm to 3200, upshifts, Boost = 10-12.
Advice/suggestions greatly appreciated.
Senior User
Joined: Oct 2014
Posts: 224
Likes: 0
More info (via SG-II) - more questions.
2 pressing issues - EGR & Turbo operation.
Initially, during mild driving (at 190*), EGR Valve Position Measured % closely follows EGR Valve Position Desired % (3-12).
After 5 minutes, Desired continues varying - but Measured goes to 0.
VGT (VGT Duty Cycle %) @ KoEo = 0.
Idle (650rpm) = 62 (Boost = .6)
Cruise (2400rpm) = 44 (Boost = 10 @ 50 mph)
WOT (3600rpm) = 31 -- (Boost max = 20 PSI @ 70-80 mph)
Actions taken so far:
Replaced MAP sensor, checked hose & manifold nipple.
Sprayed MAF sensor with CRC cleaner.
Replaced leaking hot-side turbo cac boot.
Replaced fuel filters, cleaned hfcm chambers.
Removed EGR valve & lightly cleaned (bottom o-ring slightly rubbed)
Need to thoroughly clean it & manifold port - replace gasket/o-rings.
Performed re-learn procedure.
Original issue of PCM seeming to command de-fueling upon WOT still present. It's as if a sensor is telling PCM there's a fault condition - but, no Check Gauge lamp.
Have to do 4-5 WOT runs, backing off accelerator to get rpm past 2900/4.0 Boost. Eventually, rpm to 3200, upshifts, Boost = 10-12.
Advice/suggestions greatly appreciated.
2 pressing issues - EGR & Turbo operation.
Initially, during mild driving (at 190*), EGR Valve Position Measured % closely follows EGR Valve Position Desired % (3-12).
After 5 minutes, Desired continues varying - but Measured goes to 0.
VGT (VGT Duty Cycle %) @ KoEo = 0.
Idle (650rpm) = 62 (Boost = .6)
Cruise (2400rpm) = 44 (Boost = 10 @ 50 mph)
WOT (3600rpm) = 31 -- (Boost max = 20 PSI @ 70-80 mph)
Actions taken so far:
Replaced MAP sensor, checked hose & manifold nipple.
Sprayed MAF sensor with CRC cleaner.
Replaced leaking hot-side turbo cac boot.
Replaced fuel filters, cleaned hfcm chambers.
Removed EGR valve & lightly cleaned (bottom o-ring slightly rubbed)
Need to thoroughly clean it & manifold port - replace gasket/o-rings.
Performed re-learn procedure.
Original issue of PCM seeming to command de-fueling upon WOT still present. It's as if a sensor is telling PCM there's a fault condition - but, no Check Gauge lamp.
Have to do 4-5 WOT runs, backing off accelerator to get rpm past 2900/4.0 Boost. Eventually, rpm to 3200, upshifts, Boost = 10-12.
Advice/suggestions greatly appreciated.
I would drive it with one were you can see it to make sure your not dropping fuel pressure.
Have you checked the turbo for excessive play?
Made sure the cats not plugged?
How high does ICP pressure get on wot runs?
What does maf read at idle, wot and key on engine off?
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