ERG Replacement?
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New User
Joined: Oct 2003
Posts: 5
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From: Georgia
ERG Replacement?
When my service light came on I plugged in my OBD reader and it's given me 3 ERG Insufficent Flow codes (P0401) in a row. I've never replaced one. Can anyone tell me how hard this is to replace? The local Ford dealership wants $300 for the replacement, Autozone has the part for $78. Is this an easy one to get to or is it a major overhaul?
I can't find my Chilton's... My wife packed it the last time we moved, 1 year ago, it's still hiding.
I can't find my Chilton's... My wife packed it the last time we moved, 1 year ago, it's still hiding.
Hotshot
Joined: Aug 2002
Posts: 12,679
Likes: 15
From: BC, Canada
Hi Nomadadon and welcome to FTE 
The most common cause of a P0401 is a faulty DPFE sensor. The EGR valve can fail but isnt as common and the EGR ports in the intake can also plug up and cause the code.
With the engine idling apply vacuum to the EGR valve and the engine should stall or almost stall. If it doesnt then the EGR valve is bad or the ports are plugged. If it stalls or almost stalls it probably needs a new DPFE sensor.
The valve is quite easy to replace. It is under the black plastic throttle body cover on the driver's side of the engine.
The DPFE sensor is near the valve. It is a small sensor sitting on top of 2 hoses that run to the pipe that goes from the exhaust manifold to the EGR valve. If it needs a new sensor I would buy one from Ford and not an aftermarket one.
Also if you do a search in the forum here you'll find lots of info on the trouble code you have.
The most common cause of a P0401 is a faulty DPFE sensor. The EGR valve can fail but isnt as common and the EGR ports in the intake can also plug up and cause the code.
With the engine idling apply vacuum to the EGR valve and the engine should stall or almost stall. If it doesnt then the EGR valve is bad or the ports are plugged. If it stalls or almost stalls it probably needs a new DPFE sensor.
The valve is quite easy to replace. It is under the black plastic throttle body cover on the driver's side of the engine.
The DPFE sensor is near the valve. It is a small sensor sitting on top of 2 hoses that run to the pipe that goes from the exhaust manifold to the EGR valve. If it needs a new sensor I would buy one from Ford and not an aftermarket one.
Also if you do a search in the forum here you'll find lots of info on the trouble code you have.
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New User
Joined: Oct 2003
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From: Georgia
Ok, EGR, knew ERG didn't sound right, that's the sound I make when the light comes on.
What are the full names for this? I found my Chilton's and there's no reference for EGR or DPFE.
I'll see what I can do about applying vacume tonight. I don't think I have any mechanism for that or even a hose I can attach and have my 6yr old suck on.
What are the full names for this? I found my Chilton's and there's no reference for EGR or DPFE.
I'll see what I can do about applying vacume tonight. I don't think I have any mechanism for that or even a hose I can attach and have my 6yr old suck on.
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New User
Joined: Oct 2003
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From: Georgia
And if it matters, this is a '97 F150xlt with 170K miles (170000). I bought it used with 120K on it and it showed regular maint in the logs when I bought it but I didn't see anything about replacing something such as this.
Hotshot
Joined: Aug 2002
Posts: 12,679
Likes: 15
From: BC, Canada
EGR is Exhaust Gas Recirculation.
DPFE is Delta or Differential Pressure Feedback EGR.
Chiltons might call it and exhaust pressure sensor or something like that.
To apply vacuum to the valve you just need a piece of vacuum hose and someone to suck on it
You can probably pick up a couple feet of hose at any parts store for next to nothing.
DPFE is Delta or Differential Pressure Feedback EGR.
Chiltons might call it and exhaust pressure sensor or something like that.
To apply vacuum to the valve you just need a piece of vacuum hose and someone to suck on it
You can probably pick up a couple feet of hose at any parts store for next to nothing.
Senior User
Joined: Nov 2003
Posts: 263
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From: Royal Palm Beach, Fl
Clogged Ports
I suffered through the same problem with code P0401. You did not say what engine I changed the ERG Valve and the PDFE switch and it did not fix it. The light came back on in a few miles, but I finally fixed my 98 4.6L F150 with 112,000 miles by cleaning the ERG ports. The ports I'm speaking of can only be accessed my removing the throttle body elbow off the top of the intake manifold. It's an elbow that connects most of the vacuum lines including the ERG Valve. I got a lot of carbon out of their using a drill bit by HAND and that fixed it. There is a simple test to tell you if the ports are clear.
Remove the vacuum line from the ERG Valve and cap the hose. Start the engine and let it idle. Then apply vacuum (outside source) to the ERG Valve. The engine will stumble or stall if the ports are clear. If the engine continues to idle without change the ports are blocked and need to be cleaned. I cleaned mine in about an hour it's not that big of a deal on the 4.6L
Remove the vacuum line from the ERG Valve and cap the hose. Start the engine and let it idle. Then apply vacuum (outside source) to the ERG Valve. The engine will stumble or stall if the ports are clear. If the engine continues to idle without change the ports are blocked and need to be cleaned. I cleaned mine in about an hour it's not that big of a deal on the 4.6L
Elder User
Joined: Jan 2003
Posts: 796
Likes: 1
50th ann, i have a 97 4.6 which is i think identical to yours. is it required to pull the entire throttle body to get at the elbow? I've pulled the egr,etc for cleaning (but not the throttel body) and i think i know the elbow you refer to. The throttle body "elbow" is what the egr mounts to. Just wanted to make sure we are referring to the same part. thanks.
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Senior User
Joined: Nov 2003
Posts: 263
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From: Royal Palm Beach, Fl
Throttle Body
You are correct the EGR Valve mounts to the the elbow that is between the throttle body and the intake manifold. The throttle body mounts to the elbow and the elbow mounts to the intake manifold. You will have to disconnect the throttle body (4 bolts) and move it aside. Then remove the vacumn lines, EGR Valve and the 4 bolts mounting the elbow to the intake manifold. The ports can only be cleaned from the inside of the elbow. I used a drill bit by hand aprox 1/4" as I remember. Do not use cleaners on the elbow it has a special coating on the inside. Mine had a warning tag on it. Try not to drop anything it will go into the valley (black hole) below the intake manifold and you will not get it back.
Good Luck
Good Luck
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