Code 34 Or 334 - EGR voltage above closed limit –
Revised 26-Sep-2011 to add EGR cleaning and movement test for pintle when vacuum is applied to diaphragm
Failed sensor, carbon between EGR pintle valve and seat holding the valve off its seat. Remove the EGR valve and clean it with carbon remover. Prior to re-installing see if you can blow air through the flange side of the EGR by mouth. If it leaks, there is carbon stuck on the pintle valve seat clean or, replace the EGR valve ($85-$95).
Recommended procedure for cleaning the EGR:
Conventional cleaning methods like throttle body cleaner aren’t very effective. The best method is a soak type cleaner used for carburetors. If you are into fixing motorcycles, jet skis, snowmobiles or anything else with a small carburetor, you probably have used the one gallon soak cleaners like Gunk or Berryman. One of the two should be available at your local auto parts store for $22-$29. There is a basket to set the parts in while they are soaking. Soak the metal body in the carb cleaner overnight. Don’t immerse the diaphragm side, since the carb cleaner may damage the diaphragm. If you get any of the carb cleaner on the diaphragm, rinse it off with water immediately. Rinse the part off with water and blow it dry with compressed air. Once it has dried, try blowing through the either hole and it should block the air flow. Do not put parts with water on them or in them in the carb cleaner. If you do, it will weaken the carb cleaner and it won’t clean as effectively.
Gunk Dip type carb & parts soaker:
If you have a handy vacuum source, apply it to the diaphragm and watch to see if the pintle moves freely. Try blowing air through either side and make sure it flows when the pintle retracts and blocks when the pintle is seated. If it does not, replace the EGR.
If the blow by test passes, and you have replaced the sensor, then you have electrical ground problems. Check the resistance between the black/white wire on the MAP/BARO sensor and then the black/white wire on the EGR and the same wire on the TPS. It should be less than 1.5 ohm. Next check the resistance between the black/white wire and the negative battery post. It should be less than 1.5 ohm.
Note that all resistance tests must be done with power off. Measuring resistance with a circuit powered on will give false readings and possibly damage the meter.
Let’s put on our Inspector Gadget propeller head beanies and think about how this works:
The EGR sensor is a variable resistor with ground on one leg and Vref (5 volts) on the other. Its’ resistance ranges from 4000 to 5500 Ohms measured between Vref & ground, depending on the sensor. The center connection of the variable resistor is the slider that moves in response to the amount of vacuum applied. The slider has some minimum value of resistance greater than 100 ohms so that the computer always sees a voltage present at its’ input. If the value was 0 ohms, there would be no voltage output. Then the computer would not be able to distinguish between a properly functioning sensor and one that had a broken wire or bad connection. The EGR I have in hand reads 700 Ohms between the slider (EPV) and ground (SIG RTN) at rest with no vacuum applied. The EGR valve or sensor may cause the voltage to be above closed limits due to the manufacturing tolerances that cause the EGR sensor to rest at a higher position than it should.
The following sensors are connected to the white 10 pin connector (salt & pepper engine harness connectors)
This will affect idle quality by diluting the intake air charge
Code 41 or 91. Or 43 Three digit code 172 or 176 - O2 sensor indicates system lean. Look for a vacuum leak or failing O2 sensor.
Revised 11-Jan-2015 to add check for fuel pressure out of range
Code 41 is the passenger side sensor, as viewed from the driver's seat.
Code 91 is the driver side sensor, as viewed from the driver's seat.
Code 172 is the passenger side sensor as viewed from the driver's seat.
Code 176 is the driver side sensor, as viewed from the driver's seat.
Code 43 is not side specific according to the Probst Ford Fuel injection book.
The computer sees a lean mixture signal coming from the O2 sensors and tries to compensate by adding more fuel. Many times the end result is an engine that runs pig rich and stinks of unburned fuel.
The following is a Quote from Charles O. Probst, Ford fuel Injection & Electronic Engine control:
"When the mixture is lean, the exhaust gas has oxygen, about the same amount as the ambient air. So the sensor will generate less than 400 Millivolts. Remember lean = less voltage.
When the mixture is rich, there's less oxygen in the exhaust than in the ambient air , so voltage is generated between the two sides of the tip. The voltage is greater than 600 millivolts. Remember rich = more voltage.
Here's a tip: the newer the sensor, the more the voltage changes, swinging from as low as 0.1 volt to as much as 0.9 volt. As an oxygen sensor ages, the voltage changes get smaller and slower - the voltage change lags behind the change in exhaust gas oxygen.
Because the oxygen sensor generates its own voltage, never apply voltage and never measure resistance of the sensor circuit. To measure voltage signals, use an analog voltmeter with a high input impedance, at least 10 megohms. Remember, a digital voltmeter will average a changing voltage." End Quote
Testing the O2 sensors 87-93 5.0 Mustangs
Measuring the O2 sensor voltage at the computer will give you a good idea of how well they are working. You'll have to pull the passenger side kick panel off to gain access to the computer connector. Remove the plastic wiring cover to get to the back side of the wiring. Use a safety pin or paper clip to probe the connections from the rear.
Disconnect the O2 sensor from the harness and use the body side O2 sensor harness as the starting point for testing. Do not measure the resistance of the O2 sensor , you may damage it. Resistance measurements for the O2 sensor harness are made with one meter lead on the O2 sensor harness and the other meter lead on the computer wire or pin for the O2 sensor.
Backside view of the computer wiring connector:
87-90 5.0 Mustangs:
Computer pin 43 Dark blue/Lt green – LH O2 sensor
Computer pin 29 Dark Green/Pink – RH O2 sensor
The computer pins are 29 (L\RH O2 with a dark green/pink wire) and 43 (LH O2 with a dark blue/pink wire). Use the ground next to the computer to ground the voltmeter. The O2 sensor voltage should switch between .2-.9 volt at idle.
91-93 5.0 Mustangs:
Computer pin 43 Red/Black – LH O2 sensor
Computer pin 29 Gray/Lt blue – RH O2 sensor
The computer pins are 29 (LH O2 with a Gray/Lt blue wire) and 43 (RH O2 with a Red/Black wire). Use the ground next to the computer to ground the voltmeter. The O2 sensor voltage should switch between .2-.9 volt at idle.
Testing the O2 sensors 94-95 5.0 Mustangs
Measuring the O2 sensor voltage at the computer will give you a good idea of how well they are working. You'll have to pull the passenger side kick panel off to gain access to the computer connector. Remove the plastic wiring cover to get to the back side of the wiring. Use a safety pin or paper clip to probe the connections from the rear. The computer pins are 29 (LH O2 with a red/black wire) and 27 (RH O2 with a gray/lt blue wire). Use pin 32 (gray/red wire) to ground the voltmeter. The O2 sensor voltage should switch between .2-.9 volt at idle.
Note that all resistance tests must be done with power off. Measuring resistance with a circuit powered on will give false readings and possibly damage the meter. Do not attempt to measure the resistance of the O2 sensors, it may damage them.
Testing the O2 sensor wiring harness
Most of the common multimeters have a resistance scale. Be sure the O2 sensors are disconnected and measure the resistance from the O2 sensor body harness to the pins on the computer. Using the Low Ohms range (usually 200 Ohms) you should see less than 1.5 Ohms.
87-90 5.0 Mustangs:
Computer pin 43 Dark blue/Lt green – LH O2 sensor
Computer pin 29 Dark Green/Pink – RH O2 sensor
Disconnect the connector from the O2 sensor and measure the resistance:
From the Dark blue/Lt green wire in the LH O2 sensor harness and the Dark blue/Lt green wire on the computer pin 43
From the Dark Green/Pink wire on the RH Os sensor harness and the Dark Green/Pink wire on the computer pin 29
91-93 5.0 Mustangs:
Computer pin 43 Red/Black – LH O2 sensor
Computer pin 29 Gray/Lt blue – RH O2 sensor
Disconnect the connector from the O2 sensor and measure the resistance:
From the Red/Black wire in the LH O2 sensor harness and the Red/Black wire on the computer pin 43
From the Dark Green/Pink Gray/Lt blue wire on the RH Os sensor harness and the Gray/Lt blue wire on the computer pin 29
94-95 5.0 Mustangs:
Computer pin 29 Red/Black – LH O2 sensor
Computer pin 27 Gray/Lt blue – RH O2 sensor
From the Red/Black wire in the LH O2 sensor harness and the Red/Black wire on the computer pin 29
From the Dark Green/Pink Gray/Lt blue wire on the RH Os sensor harness and the Gray/Lt blue wire on the computer pin 27
There is a connector between the body harness and the O2 sensor harness. Make sure the connectors are mated together, the contacts and wiring are not damaged and the contacts are clean and not coated with oil.
The O2 sensor ground (orange wire with a ring terminal on it) is in the wiring harness for the fuel injection wiring. I grounded mine to one of the intake manifold bolts
Check the fuel pressure – the fuel pressure is 37-41 PSI with the vacuum disconnected and the engine idling. Fuel pressure out of range can cause the 41 & 91 codes together. It will not cause a single code, only both codes together.
Make sure you have the proper 3 wire O2 sensors. Only the 4 cylinder cars used a 4 wire sensor, which is not compatible with the V8 wiring harness.
Replace the O2 sensors in pairs if replacement is indicated. If one is weak or bad, the other one probably isn't far behind.
Code 41 can also be due to carbon plugging the driver’s side Thermactor air crossover tube on the back of the engine. The tube fills up with carbon and does not pass air to the driver’s side head ports. This puts an excess amount of air in the passenger side exhaust and can set the code 41. Remove the tube and clean it out so that both sides get good airflow: this may be more difficult than it sounds. You need something like a mini rotor-rooter to do the job because of the curves in the tube. Something like the outer spiral jacket of a flexible push-pull cable may be the thing that does the trick.
If you get only code 41 and have changed the sensor, look for vacuum leaks. This is especially true if you are having idle problems. The small plastic tubing is very brittle after many years of the heating it receives. Replace the tubing and check the PVC and the hoses connected to it.
