stock 06, 125k, CEL p0402, replaced EGR valve and sensor, what now?

[BlazerOutback Powerstroke]

hello and thanks for viewing, I recently purchased my first Ford. I am counting myself fortunate to have found this 06 KR in good shape for $20k. However I have spent about $350 on a new EGR valve and a new DPFE sensor / EGR valve position sensor, or whatever you call that thing, only to have the CEL keep coming back on. I have scanned the code p0402 for excessive egr flow. Unfortunately I threw away the old EGR valve which was probably still good. When I pulled it out there was only moderate soot build up and there was NO gooey or oily residue. The truck does NOT blow any smoke, except when I first test drove it, and after replacing the EGR valve as it was blowing soot out for a minute. I have replaced the factory coolant cap as a precaution and when money permits I will install a coolant filter.

I am stumped on this CEL and am looking for any help anyone on here can offer, thank you for reading.

EDIT: I have noticed now that there is a light haze of black smoke when I step on it. More noticeable when the CEL is on.

[dannyboy950]

Since you have allready replaced the egr & sensor check the wireing and check that the map sensor tube is not plugged and the ebp sensor and tube as well. I assume you have cleared the code and it is still comeing back.

[BlazerOutback Powerstroke]

i ran the engine with the ebp sensor out and i could feel exhaust pulsing out. im assuming that means the tube is clear, also the old sensor didn't look very bad, only a light coating of soot inside. i will look into the map sensor but i could use more info, i havent even taken the air cleaner assembly apart yet.

[dannyboy950]

The map is a squarish plastic box mounted on the firewall near the a/c evap& heater lines has a rubber hose runs to a nipple mounted passenge side of intake manifold kinda between the turbo and oil filter houseing. The hose and nipple sometimes plugs o even splits the hose. Can affect pcm fuel strategy. Includes EGR and VGT settings in that strategy. Best I remember.

[BlazerOutback Powerstroke]

i removed and inspected the map sensor and the tubing. visually, everything looked fine, the tubing seemed kind of loose to me. those squeeze clamps could be moved by hand. the tube was clear of debris.

after reinstalling everything, i took the truck for a drive. the CEL came back on, and the truck would exhibit a noticeable surge while at constant throttle. codes p0402 again and p0299 turbocharger A low boost. I am concerned that the new ebp sensor is causing the symptoms of the recalled ebp sensors

[Bluedemon6.0]

I thought ebp was disabled on 6.0's I could be wrong. I think your vains are probably sticking. That would explain why you are surging. Mine had the same code after I deleted the egr. Do you have a egr cooler? I'm not questioning your knowledge of the 6.0 but I can tell you that I deleted my egr cooler and kept my egr valve.

[BlazerOutback Powerstroke]

i really didn't notice any driveability issue with the p0402 by itself. after swapping the ebp, the truck began surging. yes i still have an egr cooler. i am however planning a delete. i just want to be able to change it back come smog test time.

[05f250inmn]

I had the same symptoms with my truck about a year ago. I only had the P0299 code pulled the turbo and it was real dirty and sticking. Cleaned it and all is better.

[dannyboy950]

Originally Posted by Bluedemon6.0

I thought ebp was disabled on 6.0's I could be wrong. I think your vains are probably sticking. That would explain why you are surging. Mine had the same code after I deleted the egr. Do you have a egr cooler? I'm not questioning your knowledge of the 6.0 but I can tell you that I deleted my egr cooler and kept my egr valve.

I really don't remember if it was the 1st or second reflash that caused the ebp sensor input to be ignored and default settings used, but I do remember it caused more problems than it fixed and a subsequent reflash reenabled the ebp sensor and the pcm began useing actual readings again. Unshure which reflash it was tho.

[BlazerOutback Powerstroke]

i am going to youtube how to clean my turbo, i suppose if i have to take it out, i should do something else while im in there. good time for an egr delete?