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The DPFE (differential pressure feedback EGR) sensor is faulty and needs
to be replaced
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
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
The EGR valve is located in the engine compartment. Its should look this
An EGR valve assembly located at the front of the intake manifold.
The EGR valve is a poppet style valve (on/off only) and is controlled
by an internal diaphragm.
Fig. EGR location and associated components-California diesel
The electronic EGR valve and solenoid assembly
(3) is attached to the front of the right cylinder head (1). An exhaust
gas routing tube connects the EGR valve to the intake manifold.
Disconnect electrical connector (1) from EGR
solenoid (2). Remove two bolts (3) connecting EGR tube (4) to
valve assembly. Remove gasket located between EGR tube flange
and EGR valve assembly.
Remove two mounting bolts (2). Separate
valve assembly (3) from cylinder head (1). Remove and discard
metal gasket located between cylinder head and valve assembly. The
new EGR valve will come with a new metal gasket. You can reuse the
smaller gasket for the metal pipe going to the egr valve as long as its
not damaged.
The EGR pressure sensor is located within inches of the EGR valve. The exact location varies depending on the engine (2.5L, 3.0L or 4.0L). It is usually attached to the upper intake manifold with two small bolts.
If it's a 2.0L, 5 speed (1994-7) there are two DPFE solenoids (both w/ 3 vacuum ports) near the oil filter, which control the EGR valve. They are discontinued and impossible to find except on junked cars. (FORD #'s K5T44093-4) I have to junk my 1996 Probe if I don't find them - Missouri emissions.
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