EGR Disconnect Instructions
New User
Joined: Jul 2004
Posts: 2
Likes: 0
I need some advice and I hope you or someone can help me. My 2000 Ford Ranger and failed the emissions test because of a Code PO401: EGR Flow insufficient.
So I bought a new EGR valve from NAPA and got the two bolts off the the old EGR valve but could not get the big nut off the back that goes to the intake manifold.
I have read many posts but have not found any complaints about getting that bottom nut off. I can barely get an open end wrench around it. It seems that the 1 and 1/16th inch goes around it OK. There just isn't enough room to turn the wrench. How can I get the dang thing off and replace it with the new EGR Valve I just bought? If I get it changed and it doesn't solve the problem I am wondering how will I find the DPFE? In case that is the problem.
Thanks,
I was trying to save $ the Ford Dealer wants to charge. Now I feel like I should have gone there in the first place.
So I bought a new EGR valve from NAPA and got the two bolts off the the old EGR valve but could not get the big nut off the back that goes to the intake manifold.
I have read many posts but have not found any complaints about getting that bottom nut off. I can barely get an open end wrench around it. It seems that the 1 and 1/16th inch goes around it OK. There just isn't enough room to turn the wrench. How can I get the dang thing off and replace it with the new EGR Valve I just bought? If I get it changed and it doesn't solve the problem I am wondering how will I find the DPFE? In case that is the problem.
Thanks,
I was trying to save $ the Ford Dealer wants to charge. Now I feel like I should have gone there in the first place.
Last edited by tasian; Jul 18, 2004 at 08:13 PM.
Thread Starter
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Former Vendor
Joined: Mar 2004
Posts: 4,362
Likes: 3
From: Hendersonville, NC
Originally Posted by tasian
I need some advice and I hope you or someone can help me. My 2000 Ford Ranger and failed the emissions test because of a Code PO401: EGR Flow insufficient.
So I bought a new EGR valve from NAPA and got the two bolts off the the old EGR valve but could not get the big nut off the back that goes to the intake manifold.
I have read many posts but have not found any complaints about getting that bottom nut off. I can barely get an open end wrench around it. It seems that the 1 and 1/16th inch goes around it OK. There just isn't enough room to turn the wrench. How can I get the dang thing off and replace it with the new EGR Valve I just bought? If I get it changed and it doesn't solve the problem I am wondering how will I find the DPFE? In case that is the problem.
Thanks,
I was trying to save $ the Ford Dealer wants to charge. Now I feel like I should have gone there in the first place.
So I bought a new EGR valve from NAPA and got the two bolts off the the old EGR valve but could not get the big nut off the back that goes to the intake manifold.
I have read many posts but have not found any complaints about getting that bottom nut off. I can barely get an open end wrench around it. It seems that the 1 and 1/16th inch goes around it OK. There just isn't enough room to turn the wrench. How can I get the dang thing off and replace it with the new EGR Valve I just bought? If I get it changed and it doesn't solve the problem I am wondering how will I find the DPFE? In case that is the problem.
Thanks,
I was trying to save $ the Ford Dealer wants to charge. Now I feel like I should have gone there in the first place.
Junior User
Joined: Jan 2004
Posts: 85
Likes: 0
I am still loving being "unplugged." Averaged 22.4 last Sunday driving 3 hours from Sanford to Myrtle Beach. Filled up and left Myrtle Beach Thursday afternoon, averaged 21.8 back to Sanford. Hooked up my 7,000 boat and pulled her 2 hours up to Kerr Lake. Back and forth to the ramp two days and then 2 hours back to Sanford on a tank. She held 26.4 gallons, 404 miles on the tank. She seems a little better while towing. She comes off the line like a rocket!! 
Oh, forgot, June 03 engine build with original flash.
Oh, forgot, June 03 engine build with original flash.
Freshman User
Joined: Feb 2004
Posts: 45
Likes: 0
From: Indiana
I disconnected the EGR last week after reading this thread and have the following observations;
1. Seems to be quieter
2. Two tanks of fuel later, looks to be getting 1+ mpg increase.
3. Turbo starts to spool up around 800~900 compared to 1100
4. Did not remove the throttle plate
This is in an '03 F350 SRW build date 01/03 with a turbo back Magnaflow with the factory converter reinstalled, an AFE intake system and a Predator at the 65 HP setting. I see no reason to ever reconnect the EGR unless it's going back to the dealer.
1. Seems to be quieter
2. Two tanks of fuel later, looks to be getting 1+ mpg increase.
3. Turbo starts to spool up around 800~900 compared to 1100
4. Did not remove the throttle plate
This is in an '03 F350 SRW build date 01/03 with a turbo back Magnaflow with the factory converter reinstalled, an AFE intake system and a Predator at the 65 HP setting. I see no reason to ever reconnect the EGR unless it's going back to the dealer.
New User
Joined: Jan 2004
Posts: 7
Likes: 0
SBV and PSD, Thanks for the input. I put the 65 HP flash in tonight and and took it for test run. I'm going to need tires sooner than expected. Unbelievable power. I do think it is quieter too. Except when I get on it and then it sounds sweet. Thanks again.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
Ok ok ok...I just can't stand it anymore. If I can dig 15 - 20 seconds out of my busy schedule this evening I guess I'll pull that dang EGR plug.
I should have time since I'm passing on my weekly Tuesday night "Beer drinking / money gambling with the buddies night".
No wait...it'll take me longer 'cause I'll have to break out the little step ladder first. Maybe I'll start carrying that thing in the back of the truck.
Anyways...it seems that there is not a lot of info on the '04 engine builds regarding this so I'll you kids know what I experience.
I should have time since I'm passing on my weekly Tuesday night "Beer drinking / money gambling with the buddies night".
No wait...it'll take me longer 'cause I'll have to break out the little step ladder first. Maybe I'll start carrying that thing in the back of the truck.
Anyways...it seems that there is not a lot of info on the '04 engine builds regarding this so I'll you kids know what I experience.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
Ruint plan. 30 pack sittin' in the frig, in the garage as we speak. No beer run necessary.
Hey! I could do the Lotto run though....yeah....cool.
Hey! I could do the Lotto run though....yeah....cool.
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Senior User
Joined: Jun 2003
Posts: 401
Likes: 0
From: Stockton, CA.
Think about it, You have to have a higher amount of exhaust pressure before the turbo to build boost out of the turbo. That is how it all works.
So you will always have more exhaust pressure than boost,
So you will always have more exhaust pressure than boost,
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
That often happens when I drink to much beer. More exhaust pressure before turbo boost. 
Sorry...to easy.
But I am not happy. Cost me $ 50.00 to to unplug that goofy thing.
After I pulled the plug I told the Momma that I was gonna take the Beast for a little spin. The Momma said "Fine. You can take us all for a little spin. Right down the street to Chilli's"
So there I sat in Chilli's, family in tow, with the Beast resting quietly in the parking lot. $ 50.00 later I still can't tell if there is any diiference in anything except my wallet.
I couldn't even tell if it was running quieter because the on-board juke box was to loud. Something abount a new Ashley Simpson CD. Not sure, couldn't hear.
Guess I'll find out if the Beast runs different tomorrow.
Post Fiend
Joined: Apr 2004
Posts: 19,098
Likes: 8
From: Great State of Texas
Ok got to drive the Beast a bit today. Maybe a little quieter but hard to tell with these old time R & R ears. Seems to lessen any dead pedal. Not that I had much problem to start with. Actually seems to be somewhat more responsive overall though.
A real funny and I don't know why thing? The A/C seems to work better. Is it just because our local humidity is a little lower today?
Is it possible that unplugging the EGR could impact A/C in any way?
A real funny and I don't know why thing? The A/C seems to work better. Is it just because our local humidity is a little lower today?
Is it possible that unplugging the EGR could impact A/C in any way?
Post Fiend
Joined: Oct 2002
Posts: 11,314
Likes: 4
Hmmm...
good point -
maybe that the engine is more efficient without all the "stuff" being dumped into it and it can give more "oomph" to the a/c ???? who knows...
but again one of those we'll never know ones
good point -
maybe that the engine is more efficient without all the "stuff" being dumped into it and it can give more "oomph" to the a/c ???? who knows...
but again one of those we'll never know ones
Thread Starter
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Former Vendor
Joined: Mar 2004
Posts: 4,362
Likes: 3
From: Hendersonville, NC
Originally Posted by jdadamsjr
Hmmm...
good point -
maybe that the engine is more efficient without all the "stuff" being dumped into it and it can give more "oomph" to the a/c ???? who knows...
but again one of those we'll never know ones
good point -
maybe that the engine is more efficient without all the "stuff" being dumped into it and it can give more "oomph" to the a/c ???? who knows...
but again one of those we'll never know ones
Hey, can one of you Texas boys tell me how long of a drive it is from Houston to Dallas? Im sending in applications to both Georgia Tech and Rice here in the next month; just curious to how far the drive is. Houston is about 16 hours from where I live. Does anyone know how the standards of the school are?