Check Engine -egr-

[FexplorerV8]

Hi everyone, I'm in need of a little help, my 1996 V8 Explorer has had the check engine light on for quite some time now, I'm trying to get it fixed because it wont pass the state inspection its giving me 2 codes one that says Excessive EGR flow and Insufficient EGR flow... I replaced the EGR valve with a brand new one because the old one had a lot of carbon on it not allowing it to move, it was stuck but I’m not sure if it was opened or closed.

I cleaned everything including the upper intake manifold, got new gaskets and it gave me the light again, I'm of to auto zone to get the codes again and post them…

 

[rizzjc]

Did you replace the EGR sensor as well? I replaced that first, and it was the EGR itself, but maybe you have the opposite problem. You can measure the voltage to see if it is within spec before you spend the money on the part.
http://fordfuelinjection.com/?p=35
I just stuck some pins through the wire and took the readings.

 

[TequilaSnrs087]

It could be the DPFE sensor. They are the usual culprits when Fords throw an EGR-related code.

 

[FexplorerV8]

thanks for the fast response guys, im gonna go ahead and measure the EGR sensor, now what does the DPFE sensor look like what does it do and where is it located?

 

[FexplorerV8]

Did you replace the EGR sensor as well? I replaced that first, and it was the EGR itself, but maybe you have the opposite problem. You can measure the voltage to see if it is within spec before you spend the money on the part.
http://fordfuelinjection.com/?p=35
I just stuck some pins through the wire and took the readings.

I just noticed it has 3 cables wich ones do i measure?

 

[FexplorerV8]

alright i suck at measuring, i got .55volts on EVP and ground, im gonna try to measure the other two...

 

[TequilaSnrs087]

thanks for the fast response guys, im gonna go ahead and measure the EGR sensor, now what does the DPFE sensor look like what does it do and where is it located?

The DPFE is a rectangular black plastic or pot metal sensor usually mounted somehwere near the intake manifold if not on it. I am not sure where it would be on a 5.0. On my 4.0 it is bolted to the side of the intake manifold. There will be two rubber hoses going to it and an electrical connector plugged into it.

 

[rizzjc]

The '96 5.0 doesn't have a DPFE, just the EGR and sensor.

I think you want to measure the voltage at the EVP connector. I think VREF should just be 5v or something. I can't remember.

 

[FexplorerV8]

uhmmm let me try again

 

[FexplorerV8]

so what else besides the EGR sensor could set off those two codes?

 

[rizzjc]

Not sure. Is the sensor reading within spec? What are the actual codes you are getting (the numbers)? I assume you disconnected the battery to reset the computer to clear the codes. How long does it take for the codes to return?

 

[rizzjc]

One other thought. It could be the actual device (can't remember the name at the moment) which opens and closes the EGR, or the vacuum line that connects between them. I supposed it could be the computer itself, but that's probably unlikely. Just make sure you disconnect the battery for 10 minutes or more so that everything resets and relearns, and see what happens.

 

[FexplorerV8]

I need to take some pictures, I think a few of the hoses that attach the EGR could be replaced, and yeah I did reset the computer and the codes come back between say 5 to 10 miles...

As far as the readings go I really don’t know how to measure them, I will give it a try again today, the leads on my multimeter are not what they used to be, I cant get them to penetrate the shielding of the cables, I have used them for other things other than measuring and have lost their point, lol I need new leads =[

I will get the codes in a bit and the photos.

 

[FexplorerV8]

Ok the codes are P0401 and P0402

 

[rizzjc]

I'm still going to guess it is the EGR itself. But you can get some pins to go through the wire and then just use some small wire to connect then to your meter leads. That worked for me.

 

[FexplorerV8]

well the EGR is new so i guess im just gonna replace the hoses and if that doesnt fix it the sensor itself

 

[rizzjc]

Yeah, I did the sensor first, and it was the EGR. Go figure. Good luck with it.

 

[Turdle]

The 96 v8 has a vacuum solenoid-valve and a position sensor if I remember correctly. It isn't actual flow which is measured-rather, the position of the egr solenoid-
check the linkage and sensor-also check the vacuum solenoid and lines for leaks

 

[FexplorerV8]

sorry, i have not taken pictures

 

[ultraclyde]

I'm having the same issues with a 97 5.0 New EGR, Tube, etc etc, and it's still throwing the same 2 codes. if you find a solution, post it!