Help! My wife's 1997 Mountaineer is reporting code P0402 excessive EGR flow. EGR valve holds vacuum just fine, replaced the EGR position sensor, took off the EGR valve and cleaned the pintle - not too dirty with only 53,000 miles. Cleared the code and P0402 comes back after the first driving cycle.

I know what you're thinking - replace the DPFE sensor silly! Ah yes, there's been many a referece to the infamous DPFE sensor as being the problem. Great! I have no problem replacing it......... but I can't find the silly DPFE sensor to save my soul!

I've had the plastic intake ducting off looking for the sensor, had the EGR valve off last night looking around (thank god for the stubby 1/2" wrench for the bottom nut) and I'm about ready to pull the upper intake manifold off in hopes of finally tracking down where the DPFE sensor is bolted to the engine.

Exactly where is the DPFE sensor on a '97 Mountaineer (built in August 1996) with the 5.0?

Thanks!

 

If it was built in 96, 10 to 1 you have the early setup - and it does not have a DPFE sensor.

Do you have a tube running from the EGR to the passenger manifold? If not - don't waste anymore time looking for it.

You will probably have to replace the EGR Solenoid. It is the black cylinder next to the EGR valve. It is bolted to the end of the intake elbow...

 

Thanks, it is good to know I'm not loosing my mind as I don't think it has a DPFE sensor either. And no, there's no tube running from the EGR to the RH manifold.

Took the EGR solenoid apart a few months ago when the code started thinking that cleaning the little foam filter would fix it. I'll replace the solenoid valve sometime next week - got to pick up my new snowmobile this weekend! My toys have priority over the wife's.

 

I two days ago I got the same code, ERG ex. flow. Let me know how yours turned out. I havn't priced the selenoid valve yet. are they expensive? I have your exact suv, the original 5.0 in the Mountaineer.
thanks