'94 5.7 Strange EGR issue

[gregs78cam]

OK fellow gearheads, I have a coworker a '94 5.7L and he is having strange EGR symptoms. At very low loads/thottle position, even in P/N, the PCM is showing 100% desired EGR, but 0% actual EGR. I was under the impression that the EGR was a proportional flow not just ON/OFF. Most, if not all top end sensors have been replaced, i.e. TPS, MAP, IAC, EGR solenoid, EGR valve. When I hooked up to it it showed 3 codes, High TPS, EGR, and Knock circuit, some or all may have been from who know when. I cleared all of them to see which ones are actually set when the rough running condition happens, but nothing showed up when it ocurred. I will post back shortly with the 'log. He got it to stay in the rough running condition for an extended time at around 6 minutes.

[EagleMark]

What was the stock bin or at least mask ID?

[gregs78cam]

Stock .bin posted, Mask ID $0D.

It turns out, he may have installed the wrong EGR valve, but the original still tests ok, and ran the same as the replacement.

[EagleMark]

I looked through that entire log waiting for idle but it looks like you need to give it gas at idle to keep it running... your only getting 13.5 volts when driving, look what happens to batterey voltage when your driving and come to 0 MPH and idle at 7:24 in log, you can use the monitor to find exact time... 11.4 volts will not run EFI properly. Load test the battrey, it's bad!

Also ALDL Transmission Diagnostics says enabled?

I didn't know BCC to do exact compare but looks like all EGR settings are stock on bin I picked BHMX 5.7L 4L60E

Watch voltage at idle, if OK turn on lights and? Something is wrong with battrey and or charging system... you can unplug vacuum to EGR valve if it is seated and plug line. If it's seated it will idle and run and drive until it does Code 32 EGR test... then set code...

[gregs78cam]

Actually it idles fine. In all other respects it runs excellent for 223K miles. Problem is light throttle, like rolling through a parking lot, or even at 30+ mph when feathering the pedal it is not nearly as bad but it is there.

[1leg]

This sounds just like the problem i'm having. I switched bins and started leaning out the idle area VE cells and it has improved alot but its still there. I was thinking EGR too. I was planning to plug the egr to test it but forgot to buy vacuum port plug when i was at the store today.