Question about Ford Fusion

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My EGR tube burned a hole in the wiring harness of my 2010 Ford Fusion is this a design flaw

Engine light and picture of a wrench came on. Took car to dealership. They said the EGR tube burned a hole in the wiring harness. Is this common? 3yr warranty had just expired. Extended Warranty refused the claim. They appealed and it was overturned. Warranty is covering the cost less my decduible. Is this a design flaw or what?

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I have never heard of this problem on this model, but it would likely be caused by excessive exhaust system back pressure due to a possible faulty catalytic converter broken catalyst ceramic brick.

Posted on Oct 25, 2012

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SOURCE: 2005 MAZDA 6 "using" or "burning oil"

This problem sounds like ablown head gasket, this would make the oil mix in with the gas and would result in discolored smoke out of the exhaust pipe.

Posted on Jan 31, 2009

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My fans that cool the engine do not come on at all. The temperature climbs when I sit still. When I drive, the car seems to cool down.What do I need to do.

Posted on Mar 19, 2009

  • 1 Answer

SOURCE: 2003 Toyota Camry Se V6 has a check engine light

I had the same problem, then took my car to an expert repair shop who diagnosed the sensors and
found no problem with the car. They notified the DMV who was unaware of the problem, who then told the repair shop (John's Bascom Automotive) that they will adjust their computer system to allow a "two speed idle test". My bill was $95 and I still have to pay for a smog test after driving around for
a couple of days to clear the computer monitors, a fair amount and I gladly paid it.

John advised me that I'd get no satisfaction with Toyota or the DMV. I went to the dealership where I
bought the car and they said that the smog stations don't know what they're doing. They charge
about $100 and work around the P0500 code but it takes them about two hours to do this. I told
them that I should have been notified about the dyno none-compatability by Toyota and that Toyota
should have notified the DMV beforehand. I wonder how many speed sensors are being replaced by
unknowing smog shops around the state. I got Toyota's main customer support phone number and
will call them Monday. I'm going to get my pound of flesh ($95 worth) from the DMV next week also.

traderralph

Posted on Jun 26, 2009

  • 7 Answers

SOURCE: brand new 2010 ford fusion day bought wrench light

Tell the dealer to scan it. We have tons of people come in everyday that just want to know what the light is on for.

Posted on Dec 30, 2009

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Egr valve troubleshooting


Hi Mike, I'm glad to help! Mike in the older cars like your we've found here at the dealership the most common problem is the EGR causes a vacuum leak and the engine dies at idle. Here's how you can check it. Warm the engine to operating temperature, let it idle while taking a can of carb-cleaner or parts cleaner and spray it directly into the opening of the EGR Valve. If the engine trys to die then replace the EGR Valve. NOTE: Be sure to clean the tubes and holes that are related to the EGR. CAUTION: When using the cleaner to check the engine be careful not to overdue it and cause a fire because the cleaner is flamable. I suggest having water or fire ext handy just in case, I've never had a problem but its always good to be save then sorry. Hope this helps and have an awesome day Mike.

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A code P0400 may mean that one or more of the following has happened:
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  • Disconnect the car battery. Locate the EGR valve. You may need to refer to the owner's manual.
  • 2 Unhook the air supply hose, vacuum hose and all electrical connections. You may need the screwdriver for this.
  • 3 Remove the EGR mounting bolts with the socket wrench.
  • 4 Unbolt the EGR valve from the EGR tube with the wrench. Use a wide-mouthed wrench, which works best for this.
  • 5 Look at the EGR valve. If there are holes in the valve, it definitely needs to be replaced. If there are no holes, you may opt to clean it by spraying a half can of carburetor cleaner into the valve. Let it sit, then use a gasket scraper, putty knife, small drill bit or long wood screw to scrape out the buildup in the valve.
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    Dec 28, 2010 | 2005 Chrysler 300

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    Picture of egr valve and were it is located


    dffc43b.jpg

    Fig. 11: EGR valve and component mounting-3.0L engine


    da251ab.jpg

    Fig. 12: EGR valve and component mounting-3.8L engine

    Removal:
    1. Disconnect the negative battery cable.
    2. If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
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    5. Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
    6. Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
    7. Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
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    2. Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
    3. Connect all wiring or hoses to the EGR valve.
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    a887903.gif
    EGR VALVE IS #2.

    Please wait for second post to answer your second question....comes with a few pictures.

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    Hello! This is a somewhat common issue where there is an excessive buildup of carbon in the EGR port in the upper intake manifold.
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    52a1105.jpg
    On your vehicle, you will notice that the flexible tubes are held in place by one bolt each. If you remove these tubes from the engine side only - you will be able to clean inside the port that they connect to. I have had good luck using a parts cleaner that any Chrysler dealership sells - it makes short work of carbon build up. Once you have the ports cleaned out - reassemble the EGR tubes to the intake. Be sure to get them seated fully before you tighten them back down.


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