John Deere 2659.03 – ECU: EGR Flow Signal Out of Range High

The Exhaust Gas Recirculation (EGR) flow signal has exceeded the upper limit of its normal operating range, indicating a short to 12 volts in the EGR Delta Pressure sensor circuit. Engine power is typically limited, and Active Exhaust Filter cleaning becomes unavailable.

• 5085E
• 5090E
• 5090EL
• 5100E
• 5085M
• 5100M
• 5100MH
• 5100ML
• 5115ML
• 5090M
• 5115M
• 6110M
• 6120M
• 6130M
• 6145M
• 6155M
• 6175M
• 6195M
• 6110R
• 6120R
• 6130R
• 6145R
• 6155R
• 6175R
• 6195R
• 6215R
• 8235R
• 8245R
• 8260R
• 8285R
• 8310R
• 8310RT
• 8335R
• 8335RT
• 8360R
• 8360RT
• 8400R
• 9470RT
• 9520RT
• 9570RT
• 7760 Cotton Picker
• 7180-7980 Self-Propelled Forage Harvesters
• Vermeer D24x40 S3
• Vermeer D40x55

1. 1

   Inspect the wiring harness leading to the EGR Delta Pressure Sensor for chafed wires, melted insulation, or corrosion at the connector that could be bridging the sensor signal wire to a power source.

2. 2

   Check the cooling system for debris, as EGR temperature/flow mismatches can sometimes be triggered by underlying cooling inefficiencies.

3. 3

   Inspect EGR system components to check EGR cooler efficiency and ensure the EGR valve is not stuck or clogged with soot, which can skew pressure readings.

4. 4

   Test the voltage at the sensor connector with a multimeter to confirm if the short is in the harness or internal to the sensor itself.

1. 1

   Disconnect Power

   Turn off the machine and disconnect the battery to prevent electrical spikes.

2. 2

   Isolate the Fault

   If your multimeter testing reveals the 12V short is coming from the engine wiring harness, repair or replace the damaged section of the harness.

3. 3

   Replace the Sensor

   If the wiring harness tests fine, the internal circuitry of the EGR Delta Pressure Sensor has likely failed and shorted. Locate the sensor (typically mounted near the EGR cooler/valve assembly on the exhaust manifold side) and remove the mounting bolts and pressure tubes.

4. 4

   Install New Sensor

   Mount the new EGR Delta Pressure Sensor, reattach the pressure tubes securely to prevent exhaust leaks, and plug in the electrical connector.

5. 5

   Recalibrate and Clear Codes

   Reconnect the battery. Use a John Deere Service ADVISOR diagnostic tool to clear the ECU 002659.03 fault code.

6. 6

   Functional Test

   Run the engine and monitor the EGR flow and temperature sensor data to ensure they align correctly and the voltage remains within the specified range.