DPFE Sensor.....Wrong One

[laplaya1]

Originally posted by sholzee
Maybe I can help you out. Do you have the black plastic DPFE or cast housing, and what are any of the part numbers off the original unit

Has anyone changed a DPFE on a 1996 V8 305. I know it is near the EGR Valve near the firewall.

Is is difficult to get at.

 

[laplaya1]

I had a Ford Parts manager under my hood for 30 min with some Ford mechanics to find the DPFE Sensor.
They concluded that the 96 5.0 does not have a DPFE sensor eventough the parts books list a number for it.

I am still trying to find the cause of the OBD code P0402
Exhaust Gas Recirculation flow excess detected.

 

[sholzee]

Ford uses a EGR Valve Position sensor system on 5.0L Explorer/Mountaineer (no DPFE)

System consists of an EGR Valve Position sensor,EGR Vacuum Regulator solenoid,EGR Valve, Power Control Module (PCM) and connecting wires and vacuum hoses.

1 The EGR Valve Position sensor receives signals from the Engine Coolant Temperature(ECT) sensor, Intake Air Temperature (IAT) sensor, Throttle Position(TP) sensor,Mass Air Flow(MAF) sensor and Crankshaft Position(CKP) sensor to provide information on engine operating conditions to the PCM. The engine must be warm, stable and running at a moderate load and rpm before the EGR system is activated. The PCM deactivates EGR during idle, extended wide open throttle or whenever a failure is detected in an EGR component or EGR required input.

2 The PCM calculates the desired amount of EGR flow for a given engine condition. (The DPFE actually measures this flow in a DPFE system) It then determines the corresponding signal to the EGR Vacuum Regulator soleniod required to achieve that flow.

3 The EGR Vacuum regulator solenoid receives a variable duty cycle signal (0-100%) The higher the duty cycle the more vacuum the solenoid diverts to the EGR valve. "continued"..........

 

[sholzee]

4 The Increase in vacuum acting on the EGR valve diaphragm overcomes the valve spring and begins to lift the EGR valve pintle off its seat, causing exhaust gas to flow into the intake manifold.

5 The EGR Valve Position sensor measures the actual position of the EGR valve pintle and relays a proportional voltage signal(0-5 Volts) to the PCM. The PCM uses this feedback signal as an indication of the EGR valve opening.

In a nutshell one system uses a Differential Pressure sensor (DPFE) across an orfice tube to measure in real time the EGR flow and report the value back to the PCM

The 5.0 v8 system uses the EGR Valve Position sensor to sense how much the EGR valve is opening, and sending that data to the PCM as an indication of flow.

 

[HenriS]

O2 exhaust gas sensors

Hi Guys. Sincere condolences for the tragic event.

Finally got my problem sorted out by an American Car specialist, after the agents gave up.
My vehicle is an Australian export model, and only has 2 exhaust O2 sensors before the cat convertor. The motor is 4L SOC. It seems as if some of these models suffer from intake leaks, as the code on the computer reads "O2 sensors, mixture lean". The plenum chamber was removed, resealed and replaced, but the problem persisted. The air flow meter was replaced and the problem was solved.
The gearbox malfunction was apparently not linked to the computer/O2 sensor problem and the clutches were adjusted to solve this. So now I have all five ratios back, changing when it should and running like a dream, albeit a lot poorer, some $ 800 here in South Africa. Luckily insurance covered most of it.

 

[laplaya1]

Many thanks for the education. I now know where to to start.

 

[Haxaw]

Code P 0402, on ODB II

I hear ya on the code, excessive exhaust recirculation. This does point to the EGR valve correct. I work at Advance Auto Parts, so I know the comp system and if there was a mistake it was mine with the ordering and such. On the new valve it has a lable with XF3E-9D475-A3A on the top and it says Ford 0C29B on th side, 96 V8. I heard that it does not have the DPFE so I looked back where the valve is, should be, and the valve I have just is not the same. The valve in there looks like it has the mounting plate with gasket on the bottom with the line on top, it says Bosch on it. The one I ordered in has the mounting plate on the side and the tube hook up on the bottom. Just doesn't look right. On the back of the upper plennum where the intake connects to the throttle body, is where the vavle is correct. Is there anyway they put a V6 or a different valve in. I am going to Ford tomorrow to see if a tech can weave his way through the jungle under my hood. That thing is gonna be a ***** to change I was in my engine compartment just to see it.

 

[laplaya1]

EGR

sholzee,

Many thanks for the information on the 96 V 8 5L that does not have a DPEF.

Currently, the OBD code is PO401-Exhaust Gas Recirculation Flow Detected-Insufficient.

The EGR sensor was changed but the code comes back even after erased from the memory. I am inclined to replace the EGR or should I look at the Intake Air Temp sensor (IAT) or the Mass air flow sensor.

Any help would be appreciated

 

[Haxaw]

EGR Valve

I actually found out that the 96 V8's had two different EGR valves on them. If you look at the back of the upper plennum on the throttle body side the EGR is right there. It has a vacuum line attached to it and the sensor you replaced. Note that when you take it off the bottom bolt is 13mm or 14mm, 13mm I think but the top one is diifferent 9/16. I know on mine the only way i could loosen that bottom bolt was with a box end wrench nothing else would fit. My system has the internal EGR system within the upper plenum. The otyher sensor has a metal line that bolts on to the EGR valve itself. The bolt on "EGR tube" valve I could get aftermarket but mine was from FORD or listing at work was not the right one. that bottom nut is a duzzy so be patient the only way my buddy and I could get was to face the rear of the truck with our arm shoved in from the side and do it by feel alone.
Exhaust recirculation should be that sensor mine was excessive and now I am code free. The part numbers I gave up above should help.
Good luck!