Question about 2001 Ford Windstar

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Blocked passsage on egr system.egr solenoid faulty,engine light came on,how to fix this problem I would be very appreciate.

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  • Ford Master
  • 2,359 Answers

Check for

vacuum leaks on intake manifold,

the air tube between the air filter.

intake manifold vacuum hose.

===
clean throttle plate with Berryman carburator cleaner

SEE sample picture HERE
===

Also remove carbon built up behind the EGR valve and the EGR passage tube.

===

Vacuum leak WILL offset the intended 14.7 to 1 air fuel ratio.

More un-metered air (leaks) will lean out the fuel mixture.

Use small amount of Berryman carb clearer at potential air leak area will help you identify trouble spot.

At idle,just spray and listen for the RPM surge.

The in-rush of carb clearer will increase the RPM on the motor.

Record the problem spot(s) and address it later.

===

EGR carbon built up require 2+ hours to clean from start to finish.

You will need a new EGR base gasket before your start.

Locate and remove the EGR valve after the vehicle is cool down.

Carefully record the connector and vacuum line (for older vehicle) location by drawing an easily to follow diagram.

Remove the EGR valve.

Inspect the location of the carbon built-up inside the valve and the EGR passage tube.

SOAK these areas with WD-40 spary.

You will need a small screwdriver,cloth hanger and lot of newspaper and time to get this cleaning done right.

RE-SOAK the carbon and let it sit for over-night will also help.

One the last round,pass a shop vacuum of the EGR valve and the passage pipe.

Install the new EGR gasket and connectors.

Allow the vehicle to warm up outdoor to burn up any remaining WD-40.


Take it for a test drive.


Please rate my answer if it's useful to you.


Cheers,

Mustgo

Posted on Dec 19, 2009

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  • Ford Master
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This problem comes up alot. First, this is an emissions part and they have a longer warranty than the rest of your vehicle. Sometimes its 8 years and 80000 miles. That said you might want to at least call the dealer to see if they will honor the warranty.

Next, if they do not help you then here are a few ideas. One-the blocked passage is common problem especially on aluminum intake manifolds. You take off the air filter and ductwork up to the metal "air horn". Then look to see where the EGR valve is (round pot shaped 4"). You can remove this part and check if it is dirty and if it holds vacuum by putting a finger on the vacuum hole and pressing the valve up into the casing. If it does not hold vacuum it is bad. If the EGR is good you may want to take the "air horn" off (8 bolts) and clean underneath it and replace the gasket.

At this point you have checked 1/2 of the possible problems. You should disconnect the battery while you reinstall the "air horn" and air filter ductwork. This should take at least 10 minutes which will allow the computer to clear the trouble code. Reconnect the battery and drive your vehicle.

If still a problem, replace the Solenoid for the EGR. It has 2 vacuum lines and at least 1 electric connector and part of it runs to the EGR. Good Luck. If the dealer does not help you then my sequence will allow you to fix this with the least cost.

Posted on Jul 05, 2009

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  • Contributor
  • 11 Answers

Save by purchasing the EGR solenoid at a parts store rather than the dealer. It can be $60 rather than $160.

Posted on Jul 08, 2009

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Hi there, I have a town and country 2005 and the engine light come up. p0406. I change the valve and I still getting the light. Any ideas what to change next?


P0406 Chrysler - Exhaust Gas Recirculation Position Sensor Circuit High
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Did you replace the EGR valve, or the volume control solenoid valve?

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I have a 1998 ford escort with a check engine light on and can't get it off


Here is a list of possible causes. Some things you have already done.

EGR solenoid valve harness is open or shorted
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- EGR volume control valve stuck closed
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- Faulty EGR temperature sensor and circuit
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Read more: http://engine-codes.com/p0401_ford.html#ixzz28fATCih2

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Grand carvan gives p402 code


This is not a cut and dry fault code. This means that more than one thing wrong can set the code in the computers memory. Here is the low down on the P0402 fault code. This is from the OBD2 fault code diagnostic book.

P0402 - Exhaust Gas Recirculation Flow Excessive Detected
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Have 1999 nissan maxima code #po325 an code#po400 ?dont know what is wrong with car, check engine light on?need help please


Technical Description

Knock Sensor Circuit Malfunction
What does that mean?

A knock sensor tells the engine computer when one or more of your engine's cylinders are "knocking", that is, exploding the air/fuel mixture in a way that delivers less power and can be damaging to the engine if prolonged. The computer uses this information to tune the engine so that it doesn't knock. If your knock sensor wasn't operating properly, so that it was always indicating a knock, the engine computer's response may have been to change the ignition timing on your engine. Knock sensors generally bolt into or thread into the engine block. This P0325 code may show up intermittently or the Service Engine light may be lit constantly. Other knock sensor related DTC codes include P0330.
FB.init("dd7d9e9681341cde77587bc6a2029f6f"); OBD-Codes.com on Facebook Symptoms

You may notice drivability problems including a lack of power and perhaps some hesitation. There may also be other symptoms.
Causes

A code P0325 most likely means one or more of the following has happened:

Possible Solutions
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P0400 - Exhaust Gas Recirculation Flow Malfunction OBD-II Trouble Code Technical Description

Exhaust Gas Recirculation Flow Malfunction
What does that mean?

The exhaust gas recirculation (EGR) valve is vacuum controlled valve that regulates the amount of exhaust gases that re-enter the cylinders. The powertrain control module (PCM) determines how much based on engine load, temp, and other conditions. If the PCM detects that the amount of exhaust gases entering the cylinder were insufficient or non-existent, this code is set.
FB.init("dd7d9e9681341cde77587bc6a2029f6f"); OBD-Codes.com on Facebook Symptoms

No symptoms will likely be noticed by the driver other than the MIL (malfunction indicator lamp). However, non visible symptoms will be increased combustion temperature and increased Nox emissions.
Causes

A code P0400 may mean that one or more of the following has happened:

  • Plugged EGR passage which restricts the flow of exhaust gasses
  • Faulty EGR solenoid
  • Faulty EGR solenoid wiring/harness
  • Vacuum lines damaged/disconnected to the EGR valve solenoid or to the EGR valve
  • Faulty EGR valve
Possible Solutions

Since EGR valve designs are different, no one test will suffice:

  • Using a scan tool, operate the EGR valve with the engine running. If the engine stumbles, the problem was likely intermittent wiring problem or intermittent blockage problem
  • If engine doesn't stumble, operate the EGR valve manually, if possible. If engine doesn't stumble and die, the ports are likely plugged. Removal of valve and cleaning of all ports will be required
  • Checking of solenoid can only usually be done with a scan tool, because most solenoids operate with a duty cycle of voltage, rather than constant voltage
  • Check all vacuum lines, hoses, etc for any damage
  • Visually inspect the solenoid harness and the solenoid for damage
  • Replace EGR valve

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Exhaust gas recirculation flow reduced. Could be caused by valve or gunk in the flow path. I'll paste a little bit about troubleshooting below. If you need specific instructions for repairing your system, please reply with your engine size/type.

The Exhaust Gas Recirculation (EGR) system is designed to reintroduce exhaust gas into the combustion chambers, thereby lowering combustion temperatures and reducing the formation of Oxides of Nitrogen (NO x ).
The amount of exhaust gas that is reintroduced into the combustion cycle is determined by several factors, such as: engine speed, engine vacuum, exhaust system backpressure, coolant temperature, throttle position. All EGR valves are vacuum operated. The EGR vacuum diagram for your particular vehicle is displayed on the Vehicle Emission Control Information (VECI) label.
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COMPONENT TESTING

DPFE Sensor

  1. Disconnect the pressure hoses at the DPFE sensor.
  2. Connect a hand vacuum pump to the downstream pickup marked REF on the sensor.
  3. Using a multimeter, backprobe the SIG RTN circuit at the DPFE connector.
  4. With the ignition ON , signal voltage should be 0.20-0.70 volts.
  5. Apply 8-9 in. Hg of vacuum to the sensor. Voltage should be greater than 4 volts.
  6. Quickly release the vacuum from the sensor. Voltage should drop to less than 1 volt in 3 seconds.
  7. If the sensor does not respond as specified, check the power and ground circuits.
  8. If power and ground circuits are functional, the sensor is faulty.

EGR Valve Control Solenoid
  1. Remove the EVR solenoid.
  2. Attempt to lightly blow air into the EVR solenoid.
    1. If air blows through the solenoid, replace the solenoid with a new one.
    2. If air does not pass freely through the solenoid, continue with the test.

  3. Apply battery voltage (approximately 12 volts) and a ground to the EVR solenoid electrical terminals. Attempt to lightly blow air, once again, through the solenoid.
    1. If air does not pass through the solenoid, replace the solenoid with a new one.
    2. If air does not flow through the solenoid, the solenoid is OK.

  4. If the solenoid is functional but the problem still exists, check the power and ground circuits.

EGR Valve
  1. Install a tachometer on the engine, following the manufacturer's instructions.
  2. Detach the engine wiring harness connector from the Idle Air Control (IAC) solenoid.
  3. Disconnect and plug the vacuum supply hose from the EGR valve.
  4. Start the engine, then apply the parking brake, block the rear wheels and position the transmission in Neutral.
  5. Observe and note the idle speed.

If the engine will not idle with the IAC solenoid disconnected, provide an air bypass to the engine by slightly opening the throttle plate or by creating an intake vacuum leak. Do not allow the idle speed to exceed typical idle rpm.
  1. Using a hand-held vacuum pump, slowly apply 5-10 in. Hg (17-34 kPa) of vacuum to the EGR valve nipple.
    1. If the idle speed drops more than 100 rpm with the vacuum applied and returns to normal after the vacuum is removed, the EGR valve is OK.
    2. If the idle speed does not drop more than 100 rpm with the vacuum applied and return to normal after the vacuum is removed, inspect the EGR valve for a blockage; clean it if a blockage is found. Replace the EGR valve if no blockage is found, or if cleaning the valve does not remedy the malfunction.

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I have a ford explorer sport 2002 and my chek engine light came on it put out a code PO401 do you know what i need to buy


PO401 code means that:
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it is your EGR Valve. EGR stands for Exhaust Gas Recirculation. It is part of the vehicle emmissions system, and is used to reduce combustion temperature and pressure to control Oxides of Nitrogen. There are generally three parts to the EGR system: the EGR valve
, an actuator solenoid, and a differential pressure sensor EGR (DPFE). These things work together to deliver the correct amount of recirculation based on engine temperature, load, etc. The P0401 code means that OBD detected an insufficient amount of EGR.

Causes A code P0401 most likely means one or more of the following has happened:
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  • There is a blockage in the EGR (tube), most likely carbon buildup
  • The EGR valve is faulty
  • The EGR valve may not be opening due to a lack of vaccuum
Possible Solutions In fixing this code, it is quite common for people to just replace the EGR valve only to have the OBD code return. The EGR valve is not always the culprit.
  • Use a vacuum pump and pull the EGR valve open while monitoring engine RPM's & DPFE voltage. There should be a noticable difference in RPM's with the EGR open
  • Clean out the EGR valve and/or tubing to remove deposits
  • Check the voltage at the DPFE, compare to specified values (refer to a repair manual for your specific model)
  • Replace the DPFE sensor (with a good quality / OEM one)
  • Replace the EGR valve
LOCATION:
drivers side of the engine bay, just under the intake manifold plenum where the throttle body bolts up! If you take the air snokel off you'll see it better! It has a remote mountted vaccum solenoid with a 2 wire connector going to it that you should be able to see near the throttle body.
Follow the hose from the solenoid down to the valve and you'll find it!

hopes this helps-------lebones

Jan 06, 2009 | Dodge Grand Caravan Cars & Trucks

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