First... Wow! I've been on this forum for over 8 years and I never realized there was a diesel specific section! I've always been going to the X164 section - which is great, don't get me wrong. But I'm so happy to find this diesel section

So here's the stumper - stumping not just me, but also my local Indy. Granted, the issue is sporadic so it's hard to figure out - I get that. I guess I'm hoping someone here has been down a similar road or can offer some guidance to help figure this out?

After a certain amount of time at highway speeds (seems to be between 30 and 60 minutes) the engine will go into limp mode (no dash light "check engine" light, though). I can then clear it as I'm driving (iCarsoft), but it comes right back within a few minutes. If I'm not trailering a boat, it's not a huge deal - with the low end torque that you all know about, I can manually shift to help with power delivery on hills.

The code is 2511-1 Check component Y27/9 (left EGR positioner). Positioner signals fault.

Here's the kicker... this might normally lead one to replace the EGR valve - but I've removed it a number of times and cleaned it. Truthfully, it's not all that sooty to begin with. I can manually move the valve easily. The Indy can also hook their computer up to it and actuate it via their computer. I don't mind buying a new part, but I'm also reluctant to "throw parts at it" - especially given the price of the EGR valve.

 

I pulled the SS EGR pipe off (the one that connects to the intake). In the 8 years that I've had the truck, I've never done that. I was, in a way, hoping to see a huge blockage. Nope, barely any at all. About 2mm worth on one side of the pipe, only at the end. About 5 seconds with a screwdriver got it all scraped off.

Tomorrow, if time permits, I'lll send a snake cam in towards the EGR cooler. I have no idea what to expect

 

Station wagon not a truck FYI,

Have not scene a single thread that had this issue and reported a fix except one that the egr was clogged. Maybe K will chime in and has scene this one. The cooler will clog first usually because of the smaller passages. GL hope its a easy fix like cleaning the cooler.

 

Thanks, Quint. The part that has me confused --- well, ONE of the parts --- is that I'm not seeing how a clogged pipe or cooler (if in fact it is) would cause a "position sensor" code. Meaning, the EGR valve will open and close just fine regardless of a clog downstream. ALTHOUGH... there is a what seems to be a pressure sensor at the downstream end of the SS cooler pipe in the intake. I'm not sure if it has something to do with air flow from the EGR system or boost pressure. It's hard to find diagrams that reference this. I wish there was a set of service manuals for this car like the Bentley manual that I have for my old BMW.

 

I think there is just pricey, plug it in and do troubleshooting. Xentry I think its called.

If there are multiple sensors then possible that its a default fault for any one of them but I am just guessing. Keep us updated if ya figure it out.

 

Pics via snake of the downstream side of the EGR cooler. It's a color camera, but because everything inside is sooty, it looks black-n-white. Well, I guess it IS actually all black and no white

Overall, not really all that bad. Certainly not anything that should be causing an issue.

 

Yeah not clogged yet from the looks of it.