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Old 06-12-2013, 09:18 PM
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Code Help....

A little background....

2004 F250, 170K miles. K&N air intake with magnaflo exhaust. Everything else stock.

I recently started seeing more black smoke then normal.... especially coming from a dead stop or prior to the turbo boost kicking in....this was under normal driving conditions and worse with a load. No DTCs at this point

I had an edge with attitude that I always kept in stock mode. I took the edge out, cleaned the EGR valve and the smoked dramatically was reduced... I thought that I was in the clear, but it returned a few weeks later.

I hook up the camper.... about 7K pounds... and the truck pours an enormous amount of black smoke and loss of power under any acceleration.

Park the camper... pop in a new egr valve, change the oil and oil filer and put in two new fuel filters and clean the K&N. Truck still smokes like crazy, especially under a load.

I buzz test the injectors..they all pass... but now I pull the following codes:
(none of which triggered a CEL)

P0401; P0408; P0488; P0603; P0611; P0299; P1408 ad P2263

from my basic google seach they all seem to be related to the EGR system and turbo underboost.

I go through several diagnostics using a buddys scan tool and think I may have it narrowed down to the EGR throttle position sensor ...this is what confuses me.. I have the 04...when I bought it, it had the butterfly valve in the egr throtle body. The valve actuator (or something in the body) malfunctioned a few years back and the valve would get stuck shut and the truck would not start. After research, I just took the butterlfy valve out and have had no problems since. That was over 50K miles ago.

I unplug the EGRTPS sensor and its got oil on it....I clean it out and hook it back up.

question being... if the butterfly valve was removed, can this sensor go bad and how would it know it was not operating the valve? Also, I cannot seem to find a replacement sensor for it ...(Im thinking this must be a factory part and the sensor is built into the EGR throttle body)... sounds expensive.... that being said, can I just remove the egr throttle body (using the 05+ pipe) and bypass the sensor? what would I do with the electrical connection from that point?

Also, I am assuming that the turbo underboost DTCs are being caused by the lack of air the faulty reading the sensor is giving... is this correct?

I know in the 05+ 6.0L, the butterfly valve was removed all together because it was needless... can I just unplug the sensor or will that create more headaches? Any help? insight at all?

Thanks
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