I repaired the vac leak and redid the smoke test. The truck is idling better but only down to about 1200 and a little rough IMO. I runs just fine. I did a diagnostic check and now I am throwing code 542. I read what it means but makes no sense since I have no fuel pump issues (that I know of). I see it relates to the PCM and the possibility it is bad. At this point my thoughts are the PCM is bad or the throttle body needs replacing since it was brake cleaned and should not have been cleaned according to the sticker. Since I already screwed with the ISS, I adjusted the Idle stop screw until my RPM's increased then I dropped it until I got the lowest idle. Based on this what would be my next step. Thanks again

 

Was Code 542 from the KOEO tests or Stored Code (aka Continuous Memory)?

 

Per your PM, I see my response in Post# 2

 

Thank you. The code was not present before yesterday. I checked the codes after the vac fix yesterday. Got the 1 1 1 then the 542 popped up for the first time. Key on engine off.

 

I disconnected the battery overnight and got a cold code of 512. Then I drove the truck about 5 miles and the 512 was gone but I got a 3 3. EGR not opening. I just replaced the EGR a few days ago. ??? I just went out and disconnected the EGR and the truck started and ran. I then did a diagnostic and got a 3 2 7 . The 3 3 is gone and replaced with the 3 2 7 code. Redid it and got 327 again. That is where I left it.

 

Code 512 was caused by removing the battery cable to erase the CM codes.

Code 3 3 is not Code 33 EGR opening not detected. It's the System Pass Code 111. It's displayed twice so it's 111....pause...111.

 

I got the 3 3 after the 111 111 came on. Anyway the 33 is gone and now replaced with the 327 code. When I replaced the EGR I did not replace the solenoid. I disconnected the solenoid and tested for power to the solenoid and it is good. I don't know how to check the solenoid with it connected. My Chilton is vague and I am challenged in electrical. I drove the truck again and still get the 327.

 

Code 327: EVP circuit below minimum voltage of 0.2 volts.

I do not recall why you replaced the EGR valve? If you have the old one, put it back on.

EVP= EGR Valve Position sensor. It's the gray piece on top of the EGR valve. It is preloaded by the EGR valve diaphragm spring. A bad EGR valve, even though new, can trigger that code.

 

I have the old one but If I push the diaphragm down and cover the vac the diaphragm still returns forcefully. I can get AZ to replace the new EGR but do you think it could be the solenoid causing the code? I can get a new EGR now if you think I should. BTW I really appreciate your patience and help.

 

All you need to do is put the EVP back on the old EGR valve. Clear the codes, then re-run the KOEO tests and CM code display. If Code 327 goes away, you have a bad new EGR. IF it stays, you probably have a worn our EVP. No need to completely re-install the old EGR, just support it so the wires do not get pulled out.

Of course this means you should not start the truck to run the KOER tests...

Autozone is notorious for cheap chinese parts.

 

I connected the EVP to the old EGR but did not install the EGR. Cleared codes and 327 is gone. No codes but it has not been started if that matters. Still a bad NEW EGR?

 

Looks like it is to me.

I recall someone else tried numerous aftermarket EGRs and got the same error as you. They ended up ordering a Ford version. Problem resolved.

 

I replaced the EGR with another new one. About the same results as the first one. I took it to a friend and he smoke tested it and the EGR looked like a BBQ pit. Got a Borg Warner with lifetime warranty and we installed it. It was like a different truck. Got the idle to about 900 or so and running pretty smooth at idle. When I left I got a CEL 332 and cleared it and got it again. Turned around and we put the smoker on it again. Nothing. Still 332. I am putting a new EVP sensor on it tomorrow as that is about all left to do at this point. Will let you know what happens and wanted to update on your help so far. Thanks again.

 

Code 332: EGR valve opening not detected.

Verify the EGR valve is opening when vacuum is applied.

 

I replaced the sensor. Idle came down some but still throws 332. It will clear, but in gear a few feet and it's CEL time again. The EGR diaphragm is not opening cold or at operating temp.

So I have proper power from the motor to the evp connection. The connection to the evp and the sensor connection and evp are new. The EGR is new, 3rd one. I have smoked tested twice. The only thing I can imagine now is the PCM is bad but I don't know how to check it. If you think I should check the pcm can you tell me how. I have a Meter but am challenged with it. Or, do you have another idea I can try. Sandy