I could not find any potentiometers smaller than 5k ohms at Radio Shack, and was not willing to wait around for Digi-Key/Mouser to ship me one.
So, I put a 1-pin weatherpack connector on the wire extension I installed yesterday, then installed a 1-pin weatherpack jumper with a 220 ohm resistor on it. Now, I can very quickly switch between stock and added resistance. Hopefully, the 220 ohm resistor will be small enough to be acceptable by the engine computer. If not, I might as well go to plan B above, because I just don't see that it's possible to get any sort of meaningful increase with anything smaller than 220 ohms.
I've added the below table in an attempt to illustrate the # increase in EGR valve opening with the added resistance. "Stock" is what the engine computer would get if it commanded the EGR valve open at a certain percentage, without the added resistance in-line with the position sensor. With the feedback from the valve position sensor with the added in-line resistance, the EGR valve would open to the "modified" percentage value.
% EGR Opening, Stock and with 220 ohm resistor added
Stock | Modified |
0.0 | 0.0 |
5.0 | 5.4 |
10.0 | 10.8 |
15.0 | 16.2 |
20.0 | 21.6 |
25.0 | 27.0 |
30.0 | 32.5 |
35.0 | 37.9 |
40.0 | 43.3 |
45.0 | 48.7 |
50.0 | 54.1 |
55.0 | 59.5 |
60.0 | 64.9 |
65.0 | 70.3 |
70.0 | 75.7 |
75.0 | 81.1 |
80.0 | 86.6 |
85.0 | 92.0 |
90.0 | 97.4 |
95.0 | 100.0 |
100.0 | 100.0 |