EGR Valve Disonnect Problem
New User
Joined: Jan 2005
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Originally Posted by Tuggingafiver
can certainly assure you that all 2005s do not engage the check engine light or any other engine lights with the EGR unplugged,,
been out for several thousand miles now,,
been out for several thousand miles now,,
Sweet! hope this is true....Rob
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Senior User
Joined: Jan 2005
Posts: 416
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From: Pittsburgh, PA
To answer the question above. I bought my truck in Pittsburgh.
The truck runs great pluged and unpluged. I tried it again last night. Shut the truck off, and unpluged. No light for about 2 minutes then, there it is again. SO I plugged it back in, cleared the codes and the engine light went away. I guess I am stuck with it.
The truck runs great pluged and unpluged. I tried it again last night. Shut the truck off, and unpluged. No light for about 2 minutes then, there it is again. SO I plugged it back in, cleared the codes and the engine light went away. I guess I am stuck with it.
Senior User
Joined: Oct 2004
Posts: 157
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From: Orange County, California
My CEL light came on after 4 starts even with a dummy EGR plugged in. 2 codes thrown, 401- EGR Flow insufficient detected and one other. California 04 truck. Driven off road when testing.
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Is that right?? Wow...I just bought a "dummy" EGR..cost me $289 new. If that's the case...there must be another sensor involved? How did you place the dummy in your engine compartment? Did you enclose it or just lay it on it's side? Maybe if it wasn't enclosed and secured...it could have a problem when you are off road?
New User
Joined: Jan 2005
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Originally Posted by dogdude2003
Is that right?? Wow...I just bought a "dummy" EGR..cost me $289 new. If that's the case...there must be another sensor involved? How did you place the dummy in your engine compartment? Did you enclose it or just lay it on it's side? Maybe if it wasn't enclosed and secured...it could have a problem when you are off road?
Is your truck from CA also, I hope so and if so how did you mount your thanks Rob
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Senior User
Joined: Oct 2004
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From: Orange County, California
I just layed the dummy egr on its side adjacent to the real one. It sits nicely in a little valley. I wrapped it in a paper bag with rubber bands around it. Pretty crude, but I have seen duct tape holding sensors on Delta 4 rockets, so what's the diff....? Sometimes I put some zip-ties on the ends of the dummy to secure it, but it rides pretty good just laying there. Sometimes the CEL light will turn off for a few starts, but it will turn on again later anyway. The dummy may have been a waisted effort. If you end up not wanting yours, you could probably unload it on Ebay for about $140.
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Well...if it doesn't work...I will return it for a full refund less the stupid restocking fee. I don't understand the difference between the Calif. truck and 50 states if it's connected to the circuit. It's basically a mechanical switch that opens and closes. It is closed on idle and open on drive. If the computer senses that it is opening and closing...why wouldn't it keep the light off? hmmm Anyone know??
Senior User
Joined: Oct 2004
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From: Orange County, California
It is the 401 code that triggers the CEL light. I checked it with my code reader. "Insufficient EGR flow detected." No way around it that I know of. What I don't know is whether the 401 code triggers the "derated power mode". I have gotten used to the CEL light on and it doesn't bother me. It doesn't trigger a "limp home" mode in any event.
Senior User
Joined: Mar 2004
Posts: 394
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From: s.f. bay area
I'm guessing here, but maybe there is another sensor in the EGR flow path that doesn't detect any flow when the valve is supposed to be open. The PCM knows the valve is open/closed, since a real valve is plugged in, but with it in the open position, there should be exhaust flow, and since the "other" valve is closed, it prevents flow setting off the code?? This all makes sense if there is some way to detect actual flow of exhaust from somewhere else.
Senior User
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There are two sensors, I found out that average flow, etc. and if they do not sense exhaust flow, it throws the 401 code. I'm told I can get an update from SCT to flash my PCM to not show the CEL on the 401 being thrown. So..you need a dummy or disconnect and a way to flash the codes away.
I'm going to return the dummy tomorrow and try to get SCT to give me a custom update for removal of the CEL EGR problem.
I'm going to return the dummy tomorrow and try to get SCT to give me a custom update for removal of the CEL EGR problem.
Postmaster
Joined: Aug 2003
Posts: 4,483
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From: Central Texas
This is from the Ford Service Manual:
Do you have a good ground on your dummy EGR?
Circuit Function
The exhaust gas recirculation (EGR) actuator is a variable position valve that controls the amount of exhaust that enters the intake manifold. The EGR is controlled by the PCM using a pulse width modulated signal that varies from 0-85%. The EGR actuator consists of two components, a valve with actuator (solenoid) and a position sensor to monitor valve movement. The EGR sensor is a potentiometer sensor. When the EGR receives a 5v reference signal and a ground from the PCM, a linear analog voltage signal from the sensor will indicate position of the EGR valve.
Fault Detection
The PCM will detect an open or short in the EGR control circuit after the KOEO test has run and set a DTC. The EGR actuator can be tested for a stuck or sticking valve by performing an output state low test while monitoring EGRP percentage.
The exhaust gas recirculation (EGR) actuator is a variable position valve that controls the amount of exhaust that enters the intake manifold. The EGR is controlled by the PCM using a pulse width modulated signal that varies from 0-85%. The EGR actuator consists of two components, a valve with actuator (solenoid) and a position sensor to monitor valve movement. The EGR sensor is a potentiometer sensor. When the EGR receives a 5v reference signal and a ground from the PCM, a linear analog voltage signal from the sensor will indicate position of the EGR valve.
Fault Detection
The PCM will detect an open or short in the EGR control circuit after the KOEO test has run and set a DTC. The EGR actuator can be tested for a stuck or sticking valve by performing an output state low test while monitoring EGRP percentage.
Postmaster
Joined: Aug 2003
Posts: 4,483
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From: Central Texas
Dieselhound, what is a limp home mode? I think you are referring to the fact that a PCM will default to an established set of parameters if it detects that the EGR or any other sensor is "out of range". The truck will still run fine. Some have noted that they get a pound or two less boost with the EGR disconnected than they do with it connected. Something you can live with and most people wouldn't notice.