1993 Check Engine & Idle Issues | Ford Explorer Forums

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1993 Check Engine & Idle Issues

exploree

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Joined
March 23, 2011
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City, State
Los Angeles
Year, Model & Trim Level
'93 Sport 4x4
Hi,

I'm running into a Check Engine light issue once again after many years of no issues. It all came about after I took my truck into a shop and the mechanic repaired a water leak that required removing the intake manifold. I came to the shop by a recommendation, but the mechanic wasn't working their anymore. So, I opted for the guy that took his place.

That mechanic created a larger problem as I found after the repair. The CE light and an extremely rough idle were brand new problems. Worse, he or none of his fellow mechanics had the ability to figure out what the trouble codes were. The repair job was the start of these new issues. A CE and a rough idle that was intermittently dropping down to about 550/600 rpm every few minutes. Sometimes, the engine would almost die. The owner saw the problem and knew his hired gun had made an error and did not have the ability to fix the problem. I got my money back yet with another headache. This was not a good feeling after knowing the work he'd done.

Meanwhile, coincidentally enough, I needed to get the truck smog tested. I took the car in to another shop who said they would see if it passed smog and, pull the codes at the same time.

My hydrocarbons did not pass the 25 mph test with a reading of 149. Also, the codes they came up with were: 172, 173 and 336. They did their test with KOEO. However, they quoted me Right and "Left" O2 sensors and, EGR repair. Although, they did not specify what they would repair would be with the EGR. They just quoted me $400.

I know that O2 sensors can be a common repair item for these emission issues, yet I was a bit reluctant since this Check Engine and rough idle happened immediately following the removal and replacement of the intake manifold. Also, years ago I had a bad experience with a mechanic who tried to troubleshoot a similar rough idle I was having at that time. The issue eventually was resolved with a Mass Air Flow sensor. But that was painful as the initial mechanic unsuccessfully replaced EGR, TPS, L & R O2 sensors which never changed the idle problem. Mass Air Flow with a vacuum line was the answer and the dealer was involved at that point.

With a few scrapes, I decided to take the forum's tips and check for myself what is going on. I wanted to know about all the idiosyncrasies of what might be occurring and not just throw parts at this. Thank you to MrShorty's Code Pulling tips and all the other great people in here who contribute so much of their knowledge and experience. With just a little forum feedback, I know I'll get the proper advice on how to proceed. Hey, maybe this will help someone else as well.

First, I reset and cleared the codes as prescribed after the shop checked them. I want to see what I could muster up with a fresh start. Then, I drove over ten miles to get the codes activated again. The CE light comes on again intermittently as usual.

Connected my jumper wire from Pin 2 of the wire harness to the test connector. Got into the vehicle and turned the key on and proceeded with KOEO test.

KOEO: 111

CM: 172, 173 (Right O2 sensor indicates Lean...indicates Rich)

KOER: 538 (insufficient RPM during KOER Dynamic Response Test)

*Note: That seems appropriate as the RPM's were dropping. That's the one issue I have. The test did not continue any further.

I did not get the 336 code (Pressure feedback EGR Circuit voltage higher than expected) as the mechanic at the smog place did earlier. Tested it over again several times to make sure.

Btw, when the rough idle is occurring, removing each of the 3 plugs that are on the injector coil on the right side does not cause the engine to run any rougher. Only these three, when removed, do not change idle performance when it is already running poor. And, spark is still occurring on them. It seems as there is a connection with these cylinders. Maybe being rich, and flooding intermittently or, ???

Does this still seem related to replacing the Right bank O2 sensor?

Or, is that just an emissions issue and different from the rough idle?

The mechanical coincidence that set this check engine light off with the rough idle is one that I thought might save time when assessing the problem.

Still, I'm wondering...was the work that was done on the intake manifold capable of setting off these codes and causing a rough idle?

The other mechanic ran some brake cleaner around the manifold to check for vacuum leaks. No leak detected.

Also, if this is an O2 sensor, should I replace both O2 sensors as a precautionary step?

Thanks,
 



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Ok hold on to ya britches! Here we go, :)

EDIT: read the red letter statement at the bottom of the post first!

koeo 111 = system pass.:thumbsup:

koer 538 requires input form the brake pedal and throttle pedal at the right time during the test. If you don't get it right you get 538 so ignore it.:thumbsup:

Right now I'm feel'n the 336 is your only "real code":mad:

which is this part:
https://www.google.com/url?sa=i&rct...l79pHntFfOVUpvjd5c_wHBMQ&ust=1387504616725504

You want the one with the "D" shape connector Part # EGR 151

Very common failure get the lifetime warranty!

I replace mine every 4 months or so.

No known fix...Bad design on this one.. just have to live with it.

The failure is due to condensation, so weather changes, it dies, gas companies switch from winter to summer blend, it dies, etc. ect.

This will cause all manner of idle problems, knocking, lean-rich detected at o2's ect.

Which takes us to your other codes..lean-rich at o2's.

These codes are not telling us that the O2's have failed, but that there is a problem causing a lean-rich condition.

Now the other buggie whompass is this cheap little guy.

The temp sensor for the PCM ( there are two temp sensors) one for the gauge and one for the PCM (computer)

One temp sensor is in the thermostat housing the other is near it.

The one "near" The housing for the PCM looks like this.

It is a bad Temp sensor.
getimage.php

http://www.rockauto.com/catalog/moreinfo.php?pk=951148&cc=1119631

Been here, done that already on the 94.

There are (2) sensors, so make sure you change the one that has a cone on the end of it, next to the thermostat housing.

OK so do the EGR 151 first.

Then disconnect battery, reset the codes..you know the drill

Then test drive.

Still rough idle? Then change the temp sensor.. rinse-repeat

Motor on!

Hope this get's you go'n .... And Merry Christmas!

OH! and get this..and this could be funny! in hind sight anyway.

The mechanic may have simply reversed the rubber hoses connected to the EGR 151! they are different sizes but a knucklehead could force the skinny one on the wrong pipe! Or they may have come off.

For sure check this first..:D
 






Right now I'm feel'n the 336 is your only "real code":mad:

which is this part:
https://www.google.com/url?sa=i&rct...l79pHntFfOVUpvjd5c_wHBMQ&ust=1387504616725504

You want the one with the "D" shape connector Part # EGR 151

Very common failure get the lifetime warranty!

I replace mine every 4 months or so.

No known fix...Bad design on this one.. just have to live with it.

The failure is due to condensation, so weather changes, it dies, gas companies switch from winter to summer blend, it dies, etc. ect.

This will cause all manner of idle problems, knocking, lean-rich detected at o2's ect.

This is great info. :thumbsup:

What a coincidence. I was just reading a post about diagnosing the DPFE sensor and its issues. And, "wildbill" was replying to some of the specifics. Kind of interesting considering his background working with the company who designed the sensor. Check it out:

http://www.explorerforum.com/forums/showthread.php?t=164517

This is a good little read into how Ford was attempting to fix a known issue. Perhaps if they radically re-designed it, there would be no need to be checking these for failure so often.

I really shouldn't do this tonight, but I'm tracking the part down right now.

:salute:

Thanks for your input FR-425, I'm getting down to business. Will report soon.

:D
 






Hey FR-425,

The EGR-151 made a difference, but still on occasion, a bit of unstable idle makes its presence known. But it has taken on a subtler rhythm. It is not bouncing as bad as it was. Just drops to its lower idle and remains at a softer pace. Also, maintained a higher, static idle (750 RPM) for a much longer period before dropping to the 550 RPM.

This was a good call seeing that this EGR-151 will sooner or later go south. Now that it's confirmed that I will need to continue to monitor and, perhaps replace at more frequent intervals as a part of maintenance, it's on the schedule. Got a BWD brand at O'Reilly and it has a lifetime warranty. :thumbsup:

Tomorrow I'll tackle the Coolant Temperature Sensor. Looking forward to the results. Going to reset the codes after that sensor install. As well, I have a new Motorcraft Fuel Pressure Regulator from RockAuto ready to install. The existing (original) was leaking a bit. Will put both these parts in and see how things go.

Hope things are going well on your end...Merry Christmas to you!!!

:)
 






Cool, no prob.

I to have read wildbill's stuff. and he's exactly right.

With your idle still a little rough but with a leaky fuel press reg, ya I'd be replacing that.

I'd go ahead and do the temp sens to.. the out put drifts over time and can cause poor fuel economy before any other symptoms. Pretty critical on these motors.

After you do these it will take 50+ miles driving to re-teach the PCM. After a couple days all should be back on par.

Over the last two years I have gone through and replaced all sensors on mine just to fresh everything up, 12.5 mpg to 17.2 City with a/c And a crazy 27 mpg highway!!!

$50 here $100 there, totally worth it.

I bought two EGR 151's carry one at all times.

If the EGR 151 goes south on you on the trail, you can take it off an flush it out with 90% rubbing alcohol and that will by you a couple of weeks.

Didn't like carrying :fire:flammable:fire: liquid in the cab. "smoker"
Plus it wreaks!
 






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