Where in the engine is this located? I know that it is in the air flow housing unit but if looking at the engine, what quadrant? Is there a cover on it and maybe that is why I cannot see it under the hood immediately? Can I get to it from the hood or do I need to get at from underneath?
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The P0401 code refers to not enough flow of the EGR system. Most common problem for the Ford 4.6L engine, is the flow ports in the throttle housing. If you have this code, try this procedure first, before spending any money. First remove the two EGR valve mounting bolts. Leave the pipe connection connected to the valve, then remove the air intake tube to the throttle housing. Next remove the throttle housing from the intake by taking out the screws that hold it in place, and disconnect the throttle linkage. Remove the housing and turn it over, look at the ports (holes) for the EGR valve, they will most likely be covered with carbon crud. Clean these ports out completely, reinstall the housing and tighten all the bolts, reinstall the linkage and air intake tube. Clear the code with a reader, and test.
YOU NEED TO REMOVE THE WHOLE AIR CLEANER UNIT WITH AIR FLOW SENSOR.FIRST DISCONNECT AIR FLOW SENSOR BE CAREFUL NOT TO DAMAGE AIR FLOW SENSOR WHEN REMOVING AIR CLEANER COVER BECAUSE AIR FLOW SENSOR CONNECTED TO COVER. YOU HAVE TO REMOVE AIR CLEANER ASSEMBLY BEFORE YOU CAN SEE THE STARTER.
Hi, procedure from autozone.com pasted below. Please let me know if you have any questions, and thanks for using FixYa.
The clutch driven disc often contains asbestos, which has been
determined to be a cancer-causing agent Never clean clutch surfaces with
compressed air. Avoid inhaling any dust from any clutch surface. When
cleaning clutch surfaces, use a commercially-available brake cleaning
REMOVAL & INSTALLATION
Lift the clutch pedal to its upward-most position to disengage the
pawl and quadrant. Push the quadrant forward, unhook the cable from the
quadrant and allow it to slowly swing rearward.
Open the hood and remove the screw that holds the cable assembly isolator to the dash panel.
Pull the cable through the dash panel and into the engine
compartment. On 5.0L engines, remove the cable bracket screw from the
Raise and support the vehicle safely using jackstands.
Remove the dust cover from the bell housing.
Remove the clip retainer holding the cable assembly to the bell housing.
Slide the ball on the end of the cable assembly through the hole in the clutch release lever and remove the cable.
Remove the dash panel isolator from the cable.
Install the dash panel isolator on the cable assembly.
Insert the cable through the hole in the bell housing and through
the hole in the clutch release lever. Slide the ball on the end of the
cable assembly away from the hole in the clutch release lever.
Install the clip retainer that holds the cable assembly to the bell housing.
Install the dust shield on the bell housing.
Push the cable assembly into the engine compartment and lower the
vehicle. On 5.0L engines, install the cable bracket screw in the fender
Push the cable assembly into the hole in the dash panel and secure the isolator with a screw.
Install the cable assembly by lifting the clutch pedal to
disengage the pawl and quadrant. Then, pushing the quadrant forward,
hook the end of the cable over the rear of the quadrant.
Depress the clutch cable several times to adjust the cable.
Turn the Sonata off to eliminate the risk of engine backfires while changing the air filter. Leave the car off until the filter has been replaced or there is risk of injury.
Lift the hood of the Sonata. Locate the air filter housing unit on the passenger side of the car, in the front corner. Look for a black, plastic cylinder that has an accordion-type hose attached to it that leads to the engine.
Remove the air intake hose and air duct from the housing unit. Disconnect the connector for the air-flow sensor from the filter cover. Unclip the clip on the filter cover. Lift the cover off the housing unit.
Take out the old filter from the housing unit. Remove any remaining debris out of the air filter unit. Wipe the inner and outer surfaces of the housing unit with a damp cloth.
Place the new air filter in the housing unit. Use a K&N air filter, part number 33-2346.
Replace the cover on the housing unit and clip it in place. Reattach the air-flow sensor. Put the air intake hose and air duct back in place on the housing unit.
REMOVE ENGINE COVER DISCONNECT MASS AIR FLOW SENSOR CONNECTOR.LOOSEN AIRDUCT FLOW TUBE SCREWS THEN REMOVE AIR FILTER COVER HOUSING BOLTS THEN RAISE AIR FILTER COVER UP SLIGHTLY ENOUGH SLIDE IT AWAY FROM AIRFLOW DUCT.THEN REMOVE COVER REPLACE AIR FILTER THEN PUT EVERYTHING BACK UP VISA VERSA DONT FORGET TO TIGHTEN SCREWS TO AIRFLOW DUCT TUBE ONCE AIR FILTER HOUSING BACK IN PLACE.
INTAKE AIR TEMPERATURE SENSOR (IAT) is normally located at the engine air filter housing for old models but i think yours its incorporated with the mass air flow unit (assembly). Thats the sensor after the air filter
Check whether water is coming out of the air bleeder pipe behind the carburator. If not, the heater unit water flow is blocked. You can notice this when turning off the engine. You can hear the water grumbling. at the back of the engine. Normally when it overheats the water flows back to the expansion tank and water will overflow through the cap. Make sure you are bleeding the air well after working on the water system of this car.