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The sensor is a good call. It is also possible you just got a bad EGR valve. There was a string of them for a while. I have no idea how you would test one and they are kind of expensive to just throw at it.
I was thinking about how I would test an EGR valve, and it occured to me that since you have a spare valve already, you could plug the spare one into to harness and just let it lay on top of the engine. Then get her warmed up on a drive and check it for movement. My Edge Insight lets me watch the commanded EGR in percentage, so I know when it is supposed to be open, but without that I think you can expect it to be open at least a little whenever the engine is hot and at an idle.
Right now we know you either have two good valves, or two bad valves.
Well I removed the valve again and cleaned out the housing as much as I could. I got a bunch of sludge out of it and it worked for about 50 miles of in town driving. It usually doesn't come on until I'm doing between 25MPH and 35MPH in town. What could cause that? It doesn't come on during hiway driving.
Did you pull that sensor? Pull it, inspect it, clean it, reinstall it. It is easy to get to.
Are you talking about the IAT2 Sensor. If so I did not pull it. But I will. I have to remofe one of the turbo cooling hoses It's just got some hose clamps on it. I just hope that I don't mess that up. They cost some money down here.
Yes, the IAT2 as Steve Bricks suggested early on. I was looking at mine last week and I thought it would come right out, but not positive. If anything you might just be removing the hose between the air filter and turbo inlet. You can't screw that up. Just be careful with the MAF sensor connection.
As badly caked as you described the EGR valve to be, I wonder if the IAT2 sensor is gunked up enough to where it's not reading the air temp properly, and the pcm thinks there's not enough EGR?
Maybe one of the techs can help out with that one.
Took the IAT2 Sensor out and Yes it was gunked up as well. I cleaned it off and haven't gotten a code as yet.
Will keep you posted.