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I have a 1996 E.B. 5.0L .Check engine light has been on for a while , I finally got codes read. Insufficient egr flow detected came up, the guy at advanced auto assured me it was the egr valve, $60 dollars later installed new egr valve and reset computer, 30 miles later light is back on with same code. How could i diagnose the problem? thanks.
Check for vacuum leaks first. Those plastic hoses crack easily and it can cause "insufficient flow" if vacuum can't get to the EGR valve.
Does '96 still use a sensor on top of the valve? If so that could be your problem. It can be tested with a voltmeter and vacuum pump.
If those check out fine, it's probably the EGR vaccum regulator (EVR). It's on top of the engine near the coil. It's a fairly cheap part from Ford (no parts store I asked could get one).
I am not sure about the 90's models but the 80's had a tube the ran from the back side of each hea and if it became clogged it would send the EGR as being bad .......by the time i figured it out , mine all ready had a 4BBL and headers
'96 uses a DPFE setup. There's a sensor box mounted on the box and it measures pressure from several places. It's more complicated than what you find on the '86-95 setups.
I've emailed the test procedure; check your email. If anybody else is interested, enable your email and let me know.
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