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Solved 1401 Code. Not sure what else I can dooo

Prefix for threads that contain problems that have been resolved, and there is an answer within the thread.
You know we need a video of soap suds start up.

Looked again at the pictures and see foam bubbling through the egr nut threads. Nice. That should help free it. The lower fitting is threaded also. I'd remove it, clean the threads and thread seal it tight, then put the egr nut back on.

It will most like make the manifold leak worse

If you do go in to remove manifold bolts, tap the wrench with a hammer to pop them loose. Best way to avoid breaking them
 



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@Turdle

I'm concerned about the egr bung on the manifold.

the leak appears to be the threaded part that attaches directly into the manifold side.
NOT on the egr tube side.

I tried to tighten that today with no luck. Is there a way to seal it?
perhaps take manifold all the way off so I have leverage to tighten it?
Is it even threaded to manifold?

Do I need to buy a new manifold to be sure the bung is sealed?

Asking because I don't want to replace the gasket only to find the bung is still leaking.

Side note: I happen to have an exhaust leak in exactly the same egr location on my '90 F150.....oy, these fords and their exhaust leaks!

Thx
 






I thought it was threaded in. If you can get the nut off, loosen other end at egr and move egr tube out of the way you'll have access to it. It may be a pressed fit. If it is, high temp jb weld might seal it
 






Sooo.... it didn't fix it.

Un-frickin' believable...!

Replaced exhaust manifold gasket on right side of engine.
Got the EGR Bung on manifold tightened/sealed. (FYI: It IS threaded}
Tested the system (made video, but can't seem to upload it).
Also tested the EGR Tube for leaks.
NO LEAKS!

Threw the code.

Went ahead and replaced the EGR valve itself just in the off chance maybe it is not functioning properly
when engine gets hot or some such.

Threw the code.

What else is there ?
Vacuum lines all look good.
Cleaned all the orifices .
I've replaced everything in this diagram.

20231119_205955.jpg


Side NOTE:
Replacing exhaust manifold gasket not as bad a procedure as I anticipated.
Soaked all the bolts for 2 nights in a row with fREE ALL and nut buster.
They came right out no problem
Easier through wheel well with wheel off.
Removed oil fill tube, air intake, EGR tube
IMPOSSIBLE to get exhaust pipe bolts off manifold, but didn't need too. Left if on and was able to maneuver gasket.
 






You've done your share of work!

It's gotta be either the egr vac regulator solenoid, or possible bad electrical connection, maybe at pcm connector. Have you reseated the pcm connector? While it's off, look closely at the pins for the dpfe sensor to pcm.
 






I replaced the solenoid w new one.
Are there any other vacuum related regulators or "hubs"?

seems like any leak in a vacuum line would result in EGR staying closed and a LOW Flow code not high flow,
but if there is a crack somewhere in a Vac. Hose could it cause this?


I'll look for connector to pcm.

There is small exhaust leak on driver side exhaust, but I don't see how that would affect it as it is not connected to EGR circuit.

Could cleaning the MAF help?

Thanks for hangin' in on this.
Appreciate it.
 






@Turdle

Could it be the orifice in the EGR Tube is messed up?

how can I know which pins are for dpfe?
is this the PCM?
PCM.jpg


And what is this? With the vac. line on top.
unidentified.jpg


Thx.
HOpe you had great thatnksgiving.
 






Second pic is fuel pressure dampner,

Red vacuum is fuel control, green vacuum indicates emissions vacuum. White is source vacuum.

I suppose the orifice could get out of spec,


First pic is the pcm connector. You might fix an issue by merely re seating it. Sometimes that bolt in center is loose, which would cause who knows what.

Also while you are at it, re seat the square connector on firewall right above intake manifold, has same center bolts.

Would need schematic to locate pin numbers for egr- dpfe. Haynes might have that.
 






tried reseating the connectors.
no luck.

I have an EGR tube ordered. And will try it, though I have a feeling it isn't going to fix the problem.

With engine running I pulled the vacuum line off the EGR valve. Didn't hear any difference in way engine was running.
Vacuum at the vacuum hose was very minimal.
just fyi
 






Ok, pcm says I want egr so it switches the egr vacuum solenoid on. This should cause a differential in pressure to be seen by dpfe.

If that doesn't happen , or, the pcm doesn't see that 401 is set.

Vacuum is at egr when pcm commands solenoid .

Does engine stumble while running if vacuum is applied manually to egr valve?
 






srry for slow reply

tested it just now.

yes. engine stumbles with vacuum applied manually.

Does that indicate that the EGR system is working, and that it may be a PCM issue?
 






It does indicate the egr valve opens with vacuum.
Does not proove pcm issue. Could be non switching vacuum solenoid, or even a bad dpfe. Did you use motorcraft parts?
 






What hose type are you using for the DPFE? They are a special type of hose. I used plain rubber hose, and my ex-Ford mechanic neighbor noticed it. He dug in his garage toolbox, and handed me a pair of OEM DPFE hoses. I think he said they are silicone based.
 






:(...no, i did not use motorcraft.....forgive me for I have sinned...oy

the solenoid is NAPA Echlin
The DPFE I THOUGHT was motorcraft but going back to look at order i see it is Marketed as Motorcraft

Hoses are fuel line hose.

I see now on rock auto the hoses are actually different interior diameter by 1.6 mm.... oy, again.
 






I can't say for sure if yours is bad, but dpfe sensors are flaky when good.

Cheap beer still works, in a sense. But you can't count on cheap parts. No blame for trying.
 






Cheap beer still works, in a sense. But you can't count on cheap parts. No blame for trying.
..haha...yep...

I put "legit" hoses on. Will drive to see if CEL comes on and report back.

I have old DPFE (OEM) which I was not convinced was actually busted. Just was throwing parts at it.
I'll try to test both old and new to see if i can see......anything.
 






put the "bonified" hoses on.
No fix.

Got ANOther new DPFE and installed.
Erased codes
So far just under 100 miles no CEL
Will continue to drive. Waiting for 2 readiness codes to respond.

Holding any type of celebration that it may be fixed.

Will report back when either;
it shows it fixed it
or
I drove it into the pacific ocean and walked away
 












Hallelujah!!

Passed smog! ...can't believe it. I was sure EGR purgatory was mine forever.
It was the DPFE . Pics below of test old, new, then new new.


Thank you so much for your help!

Old DPFE
20231202_135247.jpg


1st New DPFE
20231202_135041.jpg


2cnd New DPFE
20231202_135308.jpg


vid on how to test dpfe
 



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