EGR valve issue - Ranger-Forums - The Ultimate Ford Ranger Resource


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Old 05-14-2015
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Icon4 EGR valve issue

Ok so I bought a 1999 ford ranger 3.0 v6, the person I bought it from changed the motor to a 2003 or 2004 motor. At any rate, the check engine light is on and when I scan it for codes it pulls up 1401 and 1409, which have to do with the EGR valve. The problem I have is that the motor in the truck does not have an EGR valve, but the ECM is confused because the old motor did. The motor in the truck does not even have a spot for an EGR valve. Can anyone give me any advice to help me fix this problem?
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Old 05-14-2015
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The Rangers with 3.0l lost the EGR system in 2002, 4.0l and 2.3l still had them.

Your '99 computer(PCM) has fuel strategies based on EGR working so I am sure your MPG is down slightly as well as CEL being on, could also be some pinging under load.

Person doing the engine swap should have kept old engine intakes and exhaust with EGR intact, but that ship has sailed, woulda, shoulda, coulda.......
There is no real "by-pass" solution since the Computer expects feedback from the system, it opens EGR valve using EGR Modulator, then it gets feedback from DPFE sensor on pressure changes to know how far the valve opened, and it adjusts the valve based on engine RPM and load, so it needs "real time" feedback or CEL will come on, so it isn't just a matter of twisting a few wire together or adding a resistor.
I am sure someone could design a circuit to trick the Computer, but that wouldn't be me, lol.

Contact some PCM programmers see if they can change your 1999 PCM software to newer version that doesn't require EGR system.

Or add the EGR system, yes replace upper intake and exhaust manifold, get EGR Valve/tube, DPFE sensor and EGR modulator.
Wiring for all of it should be there.


Or get a 2002 Ranger 3.0l PCM and change ignition and door locks to match new PATS keys, or get a mobile locksmith in to add your current keys to new PCM.
But not sure what other pitfalls might be involved with this PCM swap as far a GEM interface and sensor parameters.

Last edited by RonD; 05-14-2015 at 11:31 AM.
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Old 05-14-2015
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I have the spot on the exhaust just not on the intake and yes all the wiring is there I wish they would have kept the old intake but what can you expect out of 1000 dollar truck that runs and drives
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Old 05-14-2015
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I think the motor Is a 04 it has a deal on the valve cover that say it a 2004 will a 1999 or 1998 3.0 upper intake work on that motor ?
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Old 05-14-2015
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I couldn't tell you, auto parts store or wrecking yard might have that info.

You could look up upper intake gasket and see if they are the same for 1998 and 2004
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Old 05-14-2015
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the gasket are not the same now I guess I will try and find some one to reprogram it
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Or swap out lower as well, they will fit, lower intake will fit on any 3.0l, year or model of vehicle wouldn't matter.

Morana Racing sells an upper intake for 3.0l, this page: Tom Morana Racing Engines

Says it fits Ranger 3.0l '98-'06:
"3.0L Upper Intake Manifold
3.0 V6 Upper Intake Manifold
Application: 3.0L V6 Rangers
1998-06

Fully ported for better air flow "

In my mind that would mean a stock '98 upper intake would fit on a stock '04 lower intake??
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Old 05-14-2015
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ok I might have to go that way
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