John Deere 27.03 – Engine Control Unit (ECU): Engine EGR Valve Position Signal Out of Range High

The position signal voltage from the Exhaust Gas Recirculation (EGR) valve has exceeded the upper acceptable range, typically caused by a short to a 12-volt high source, damaged wire insulation, contact oxidation, or an internal electrical malfunction within the EGR valve position sensor. This causes the engine to derate and disables Active Exhaust Filter cleaning (DPF regeneration).

• 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
• 6105M
• 8310RT
• 8335RT
• 8360RT
• 7760
• 7180
• 7280
• 7380
• 7480
• 7580
• 7780
• 7980
• Navigator HDD D24x40 S3/D40x55 S3

1. 1

   Cycle Power: Turn the key switch off, wait, and cycle the tractor power to clear temporary glitches.

2. 2

   Visual Wiring Inspection: Inspect the wiring harness leading to the EGR valve position sensor for chafed wire insulation, melted wires, or oxidation at the connector pins.

3. 3

   Voltage Check: Use a multimeter to check the EGR position sensor circuit for a short to a 12V power source.

4. 4

   Mechanical Check: Verify if the EGR valve is heavily coked with soot, which can cause the valve to stick and the sensor to read out of range.

1. 1

   Preparation

   Turn off the engine, remove the key, and disconnect the battery to prevent electrical shorts during repair.

2. 2

   Locate the EGR Valve

   The valve is typically located at the entrance of the intake manifold where exhaust gas and intake air are mixed.

3. 3

   Harness Repair (If Applicable)

   If the diagnostic checks revealed a short to 12V or damaged wiring, repair the wiring harness or replace the damaged connector pigtail.

4. 4

   Remove the EGR Valve

   If the wiring is intact, the EGR valve/sensor assembly has failed internally. Disconnect the electrical connector from the EGR valve. Remove the mounting bolts and detach the valve from the exhaust/intake plumbing.

5. 5

   Clean the Mating Surface

   Remove any old gasket material and clean the mounting surface on the manifold to ensure a proper seal.

6. 6

   Install the New Valve

   Install the new EGR valve using a new OEM gasket. Torque the mounting bolts to the manufacturer's specifications.

7. 7

   Reassembly

   Reconnect the electrical connector and reconnect the battery.

8. 8

   Clear Codes

   Turn the key on. Because this fault inhibits DPF regeneration, the code may be "latched" in the ECU. You may need an authorized John Deere service tool (Service ADVISOR) to clear the code and reset the system.

9. 9

   Test Run

   Run the engine up to operating temperature under load to ensure the ECU commands the valve open and the fault does not return.