Problem, Truck SOMETIMES wont take pedal, and instead will bogg down
What we know, Check Engine Light came on and code reads as EGR Trouble
While checking the System out, we find out this EGR Switch

is sending Vac up to the Diaphram on top of the EGR Valve
http://www.robs02lightning.com/galle...lack%20EGR.jpg
BUT at the wrong time, hence bogging down the motor.
Yes it will bogg it down, we tested it with a hand Vac Pump Sal had and it did exactly what mine has been doing, so all points to the switch being stuck open. Take the Vac line off, the trouble goes away, put it on, it comes back.
So we shut the EGR down in the Chip and pulled the two lines from the switch.

Truck finally runs great, but now ocassionally it still does it, which kind of tells me maybe the EGR Valve itself is not closing correct, or staying closed.
OR
something else is faulty and was sending vac to the switch, at the wrong time

Can someone give me a understandable explanation of whats taking place and when, and even if it's turned off, if the valve is faulty, (or something else is wrong) can it still get pressure or vac in the manifold (at the wrong time) through the EGR Valve itself maybe, and still be slightly bogging it down at certain times ? Maybe like some kind of reverse flow ?

 

Well; it's been a LONGGGGGG time since I had any of the EGR stuff, but it looks like your missing 2 vacuum lines. I think I remember they were in a boot that was togeather. Maybe not....

But, if the EGR is flowing to much then yes it would bogg the motor down. Why not try turning it off in the tune and see what happens?

 

Take that stuff of rob, it takes one plate to cover the plenum part and one cap to cover the header. Then remove all the junk that goes with the egr have sal turn the code they will throw off and youll be on your way assuming this is the problem

 

that is the DPFE sensor or the differential pressure feedback EGR sensor. It monitors egr flow through the egr valve via the egr tube. There are 2 rubber lines that go from the bottom of the DPFE to the egr tube.

if you have the exact number code it would help

Will

 

Thanks Guys
Yes I know
and it is
Meaning yes the plug is off (we disconnected it)
and Sal DID turn the system off (thats whats so weird)
When he did the trouble went away, the truck was running awesome,
but then a while later the SAME EXACT prob came back ?
Sal knows the exact egr code, I'll have to find out more info on it.
(He hooked it up to an engine analizer and ran a complete system check)


Great info Spanky, THANKS
Let me ask you something, all of you. "If" the analizer is poiting us in the right direction, (and it seems it is) maybe something else in the egr system is wrong, and was sending that signal to the DPFE. Is there a way EVEN WITH THE EGR SHUT DOWN IN THE CHIP NOW, that somehow there's still too much EGR flow, and would it (or could it) still pass through the valve and effect me ??? With that thought I did take the EGR Valve off today and all seems well with it, it's working fine.

People have mentioned so many diff things that it could be, Cats, Sensors, Crank Sensor, bad Computer / Chip, Chassis Ground, Harness/Harness Plugs, Fuel return line, that sounds like a lot of money for process of elimination, and with Sal so busy I dont know when we'll get to the bottom of it.

I just got in from a nice ride and it was doing it off and on again,
so obviously I still got a problem somewhere. I think I will finally do the official EGR delete, and get it all the hell out of there, that can only help. Anyone know who sells the delete plate ?
In the mean time, back to the drawing board

 

I found some pretty interesting reading on both of these sites:

http://www.kemparts.com/TechTalk/tt02.asp
http://www.asashop.org/autoinc/nov97/gas.htm

It looks like some of the problems your having the truck might be EGR related. Hope these help man, I've been following all your threads for a while now and I can't even begin to imagine how i would feel if i was in your shoes. Can't wait to see her running and your final numbers. Keep us updated!!

 

Ford has had problem with DPFE sensors, mainly on the Focus'. It's a wicked pain in the *** and my girl's car was really wierd for the longest time before it finally threw a code.

Good luck.

 

Contact spray it racing (954) 701-0523 for the block off plate. I believe JL also has one, but I beleive it cost more. Or, you can make one using your EGR valve as a template(what I did) For the header cap just go the garden section of any store and buy a garden hose cap. Then start unbolting stuff; will make plug changes sooooo much easier.

 

the plate can be made with a simple piece of aluminum, tin snips, and drill bit and like casey said go to the garden section for the cap. Your valve could be stuck open even with the stuff unpluged so try removing it all. PLus your plug changes will be so much easier

 

Instead of buying a cap just cut the EGR tube and put a quarter inside the cap and screw it back on.

 

Awesome info once again my Brothers, WOO HOO

Great links Netoje exactly what I wanted to see.

Some interesting reading Bro, and it sounds like it DEF can be my trouble

The design challenge The EGR system of today must precisely control the flow of recirculated exhaust. Too much flow will retard engine performance and cause a hesitation on acceleration. BINGO

....system had many problems. It would often open too soon or too much, which caused a hesitation on acceleration as massive amounts of recirculated exhaust hit the combustion chamber.

A switch prevents vacuum from reaching the EGR during cold engine starts. BINGO no bogging when cold

This is quite an involved little system I see, wow
I think I'm on to something here, In Rob talk it appears we have a self testing system here that constantly checks itself for trouble, including EGR testing.
That testing does not start for the EGR til after 170 Degrees is met (BINGO, no cold start bogging problem) after the Truck reaches temp these test start,
and according to that article, the driver may feel something during the test.
They also talk about TPS and it's Voltage, and the Map Sensor.


I think if not anything else, no harm in totally removing the entire EGR system right now and see if that clears my problems, if not at least it clear's my engine compartment, WOO HOO (hey, I go to get some payback for all this time I'm putting in, hehehehe) Then I think I'll ask Sal to borrow a TPS Switch and try that (I'll check the Voltage (current setting) too of course)
Easy enough and hopefully a free test in process of eliminations. Then I'll ask to borrow a Map Sensor, then a Crank Switch, more and hopfully final steps in process of eliminations. If that dont work, it's pull the SC and start over.
Thanks everyone,
Oh well back to work, I guess it's late night and the drop light time......

 

here's the nice egr blockoff plate:

http://www.nhtoc.com/forum/showthrea...threadid=17806

(954) 701-0523

it was 12 dollars shipped for the egr blockoff and bolts.

 

I've been doing the same checks on my EGR too.
Under boost the line to the diaphram sometimes blows off.
So far I'm the only one I've heard that happening to.
I've checked the lines and all looked good and nothing connected to
the wrong spot.

I was going to replace the diaphram. I'm guessing if it is stuck open a little, it could be allowing exhaust gas in all the time and it could be allowing boost out the manifold.

I do have a EGR delete, but wanted to keep the system intact.
Good luck Rob! I need some luck too.

 

Wow Great ideas

In the middle of a brain session, I came up with this. I'll take my Mitisijapanese*******car down to the local Ford dealer. They got an 04 Lightning sitting on the lot. I'll ask for a trade-in value and to take the Lightning on a test drive.........

Are you following me. Instant access to brand new coil packs, TPS switch, Crank Trigger switch, EGR valve, hell, even a brand new unmolested wiring harness.

Sometimes I even scare myself

WOOOOOOOOO-HOOOOOOOOO's
for me

 

sounds like me and my buddys. We spotted a L that had a fluidyne H/E and a lower pulley, TB, Chip, 58" bars and a couple other items. WE test drove her for the weekend and returned it bone stock