Silver: Stupid question - the ground wire should always show continuity with the rest of the negative components/ground system of the car, even with the car switched off? The EGR flap works - can see it open and close when idling, but without going out to the garage at this late hour I do believe the EGR itself has another connector. I'll check the grounds, thanks!

Jeremy: I know what you mean about "only" $100 but that's an hour's labor at a good mechanic, who may also question the integrity of the K40. The relay may take a day to get here - my experience in my first year of ownership of this car is that even the dealer has to call up to Dallas for certain things in this uncommon engine - so worst case scenario, eliminating that possibility does have value should I have to take it back in. Best case scenario, it solves the problem.

I'm trying not to think about this too hard over the long holiday weekend, and how a coworker who has owned 2 Dodge Cummins diesels told me he's had this happen when the IP goes bad, so once I get a chance to check grounds and then order the K40 etc I'll report back any findings.

Thanks, and enjoy the day off if you can!

__________________
Charlie

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'66 VW 1300 96K miles
'97 E300D 239K miles
'85 300D 203K miles (sold Sep 2012)