Check engine, EGR code?

Tiny
JOHN FRIEDERICHS
  • MEMBER
  • 1991 FORD F-150
  • 4.9L
  • 6 CYL
  • 2WD
  • MANUAL
  • 135,000 MILES
My light came on, initially at just over 60,000 miles. The dealer said it was a "timer" for checking the EGR system that would indicate "Check Engine at 60,000 mile intervals. This was done and noted on the invoice as "EGR timer reset".
Sure enough, at roughly 120,000 miles the light came on, my code reader gave an EGR code. I called the retired Dealer mechanic who had fixed it the first time. He said to clear the code with the reader and see if it came on again. If so, he suggested that the easiest next step, rather than go through the diagnostic process, was to replace the EGR valve assembly, making sure the associated plumbing was clear. I did. Cancelled the code again, it returned after about 10 miles. He then told me to go through the process I cad used on my 1989 Bronco II which involved key-on, push and hold a button on the Controller/computer unit, turn off/turn on. It worked on the Bronc-ette. No button on this EEC. Various sources have said that the button is, variously, located 'near the fuse panel' 'under the steering column' and, my favorite, 'behind the glove box. No dice. What now? By the way, the truck runs great, averaging 18-20 MPG.
Friday, March 3rd, 2023 AT 10:58 AM

10 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,724 POSTS
Hi,

I looked through two different professional-level manuals and can't find what you are referring to.

Do me a favor. Let me know the code you found. Hopefully, that will take me to what is needed.

Take care,

Joe
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Friday, March 3rd, 2023 AT 9:59 PM
Tiny
JOHN FRIEDERICHS
  • MEMBER
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Interesting result. Ran the KOER after clearing the existing codes (if any, I didn't check). At idle there is no Check Engine lamp; that's new. Ran the test got a code, 332 insufficient EGR. Having cleaned the ports and plumbing as well as replacing the valve and actuator, which seemed odd. Ran the KOEO and got 522 not in neutral. It's a manual gearbox and was, indeed, neutral. Also got code 558 EVR circuit failure, which is new to me. Cleared, ran it all again and 522 disappeared and didn't come back, the other two did. Drove the truck two mile with the Check light on, when I parked and returned to idle, the light stayed off.
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Saturday, March 4th, 2023 AT 11:46 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,724 POSTS
Hi,

Okay, so if I understand correctly, a 558 and a 332 returned. Please correct me if I'm wrong.

The 558 is where we need to focus. The EGR vacuum regulator (EVR) circuit is failing. This could be a wiring issue, a faulty regulator, or the controller. The EGR Vacuum Regulator (EVR) is a single-unit electromagnetic device with two vacuum ports. The EVR allows the EEC Module to modulate the EGR Valve's opening to any degree, by providing the circuit's ground, internally.

The upper port (see pic 3) is connected to the vacuum chamber of the EGR Valve. The lower port is connected to manifold vacuum or ported vacuum,
I attached the start of the diagnostics. However, they are indicating the use of a breakout box. This is used to diagnose voltage and resistance issues. It prevents damage to connector pins and simply makes it easier to test. However, most people don't have one.

Take a look through the diagnostics. I included the first tests. If we need to continue further into the diagnostics, let me know and I get them for you.

Let me know if this helps or is confusing. Also, let me know if this is something you have already replaced. Keep in mind, because of the year, it could be a connector issue (corrosion, broken pin). Pic 4 below shows location.

Take care and let me know.

Joe

See pics below.
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Sunday, March 5th, 2023 AT 9:00 PM
Tiny
JOHN FRIEDERICHS
  • MEMBER
  • 6 POSTS
Well, I replaced the EVR (the old one was one of the first components replaced by the tech) and no change. The EEC connector and contacts are pristine. Checked for vacuum from the source and the operation of the EVR. It opens and closes fine. Re-checked the EGR plumbing for obstructions. Also verified the operation of the switch on the EGR valve. It opens and closes when the plunger is operated. I'm out of ideas and considering a piece of electrical tape over the check light.
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Thursday, March 9th, 2023 AT 11:49 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,724 POSTS
Hi,

I understand your frustrations. By chance, were you able to perform the aforementioned testing/diagnostics?

Let me know.

Joe
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Friday, March 10th, 2023 AT 9:09 PM
Tiny
JOHN FRIEDERICHS
  • MEMBER
  • 6 POSTS
Since I retired, I no longer have access to a proper breakout box, so my ability to run all the diagnostics is poor. I've never been a fan of throwing parts at a problem but given the remote area where I live my options are limited. I think I'll give up for a while and keep my eye out for a proper box on the used market.
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Saturday, March 11th, 2023 AT 9:13 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,724 POSTS
Hi,

I understand. Do me a favor. Keep in touch and let me know if you find one. I will keep my eyes open as well.

Take care,

Joe
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Saturday, March 11th, 2023 AT 7:16 PM
Tiny
JOHN FRIEDERICHS
  • MEMBER
  • 6 POSTS
Thanks a bunch. By the way, my factory manuals version of diagnostics amounts to checking if the vac switches properly, if it does, replace everything downstream. EGR and EVR. Not what I'd call comprehensive.
Thanks again, John
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Saturday, March 11th, 2023 AT 8:20 PM
Tiny
JOHN FRIEDERICHS
  • MEMBER
  • 6 POSTS
Well. Failure. Every component of the EGR system has been replaced, the tube is clear, the exhaust system is solid, The EEC has tested good, I even replaced the O2 sensor because it was at an extreme of the allowable range. I still go back to the first time that this happened (60,000 miles) and the dealer told me he "reset the EGR Service Timer". The next time it happened at 120,000 +- miles, I opened my factory manual and it stated that the EGR maintenance time reset is behind the glovebox. There's nothing there but the heater. Various other online sources tell me that it is in the fuse paned, adjacent to the steering column. Blah blah blah. I give up. This little light of mine, I'm going to let it shine.
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Tuesday, March 28th, 2023 AT 3:03 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,724 POSTS
Hi,

I went through two manuals and still can't find anything indicating a reset button. I was able to find there is a reset module, but when I go to that, it provides only parts, and nothing is listed. However, in the same section, it discusses the reset procedure for the CEL which I attached below. I'm not sure, but this may take care of the light/reset. Take a look through it and let me know if you try it and if it helps. On the other hand, if you already tried this, let me know that as well.

Take care,

Joe

See pics below.
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Wednesday, March 29th, 2023 AT 6:25 PM

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