EGR code help needed
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Senior User
Joined: Oct 2004
Posts: 326
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From: North Alabama
EGR code help needed
I have a 97 Expedition 4.6L with 112k miles. I currently have an illuminated CEL & code P0401 "insufficient EGR flow".
I recently replaced the EGR valve & cleared the code, but this did not solve the problem & the CEL came back in a couple of days. What should I do next? I can replace parts, but I don't have any diagnostic equipment.
Thanks in advance.
I recently replaced the EGR valve & cleared the code, but this did not solve the problem & the CEL came back in a couple of days. What should I do next? I can replace parts, but I don't have any diagnostic equipment.
Thanks in advance.
Senior User
Joined: Mar 2004
Posts: 219
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From: Grand Island, NY
Check the DPFE sensor, I am not sure on a 1997 but my 2001 its located on the drivers side of engine under the plastic 5.4L cover. It maybe black plastic or aluminum, the black plastic is better and the replacement may be plastic. It will have 2 rubber hoses going to it and a 3 pin electrical connectot. Make sure the hoses are good and there are no clogs in them. The metal tube the hoses go to has an orfice in it and exhuast gas flows through the metal tube the DPFE sensors measures pressure on each side of the orfice, the difference in pressure is used to calculate exhuast flow and the sensor sends that signal to the computer.
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Joined: Jun 2005
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EGR Ports
I hear a common problem with the 4.6L, is the EGR ports behind the throttle body plug up. You must remove the throttle body to clean them out. They are two pencil eraser sized holes. I have a 5.4L and I've had the throttle body off without damaging the gasket and no leaks when re-installed, though I had a new gasket on hand. Not hard to remove. Hope this helps.
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Senior User
Joined: Oct 2004
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From: North Alabama
Originally Posted by scholzee
Any update ? did you get it fixed ?
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Joined: Jun 2005
Posts: 11
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From: virginia
Wavin
i just got done fixing the exact same problem with my 98 4.6 with 95,000 miles Thanks to all here the fix was simple and cheap too. The EGR ports on the throttlebody were caked shut. Alittle helpful advice on cleaning them that i figured out was that a 45 cal borebursh works wonders on these ports. you can buy these with a cheap pistol cleaning kit at Wally World for about 6.00 . Mine were really bad so it took a bit to clear out enough crap to get the brush in but after i did the throttlebody cleaner and brush cleaned them out great. She's running great now. hope this helps.
Jim
i just got done fixing the exact same problem with my 98 4.6 with 95,000 miles Thanks to all here the fix was simple and cheap too. The EGR ports on the throttlebody were caked shut. Alittle helpful advice on cleaning them that i figured out was that a 45 cal borebursh works wonders on these ports. you can buy these with a cheap pistol cleaning kit at Wally World for about 6.00 . Mine were really bad so it took a bit to clear out enough crap to get the brush in but after i did the throttlebody cleaner and brush cleaned them out great. She's running great now. hope this helps.
Jim
Last edited by tomcatguy14; Jun 23, 2005 at 11:00 AM. Reason: error
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P0401 - Finally Resolved
I just bought a 2000 Expedition 4.6 59.000 Miles, and on my way home form the dealership the check engine light came on. The Dealership simply reset the light, no wonder why they had me sign so much paperwork regarding no warranty. AutoZone diagnosed the problem free as code P0401 EGR insufficient flow. If you are not near a AutoZone you could barrow a ODBII scanner from you local auto parts store by leaving a deposit. They are fairly straightforward.
In research, one thing that I was confused about was terminology. Seems that every one calls the parts differently. For the sake of the tread I used the following language associated with the following context.
· EGR Valve – Looks like a little flying saucer
· EGR Manifold – Connects to the Throttle with 4 Bolts, encapsulates the EGR Ports.
· Throttle Body – consists of the Throttle, EGR Manifold, EGR Valve
· DPFE Sensor – EGR Pressure Sensor, located on the driver’s side of the throttle body, mounted on the same bracket that holds the plastic throttle body cover over the assembly, has two hoses coming out of it.
· EGR Ports – Two Ports in the EGR Manifold that Carbon builds up creating EGR Insufficient flow
After much research and trying to change the DPFE Sensor twice, I concluded that that 90% of the cases researched the EGR ports in the EGR manifold are truly clogged. I mean I spent about an hour with pipe cleaners and Carb cleaner working in the ports, I wished I had a part cleaner tub.
In your research you will read allot about the DPFE Sensor, however, before you spend the extra $60, please take some time and take the throttle body apart and clean the EGR manifold and Ports.
Note also check the hoses on the DPFE Sensor, Mine were split where they connected to the sensor. Not that I think it was associated with the problem. More of a visual resolution.
The whole project took me about 2 hours and costs about $6.00- $2 for carb cleaner, $2 for hand cleaner, and $2 for replacement hoses. Good Luck
Enclosed is the link to a very resourceful website dedicated to cleaning the EGR manifold and Throttle Body components.
throttlebodyclean.php
The only thing that he mentioned wrong is:
· Simply disconnect the fuel injection cable, it simply snaps off of the throttle body spring.
· Take the EGR manifold off of the throttle body, its easier to clean.
· If you are careful you will not need to replace gaskets.
· Throttle body cleaner and Carb cleaner have the same ingredients so I concluded they are the same. Save the Money
In research, one thing that I was confused about was terminology. Seems that every one calls the parts differently. For the sake of the tread I used the following language associated with the following context.
· EGR Valve – Looks like a little flying saucer
· EGR Manifold – Connects to the Throttle with 4 Bolts, encapsulates the EGR Ports.
· Throttle Body – consists of the Throttle, EGR Manifold, EGR Valve
· DPFE Sensor – EGR Pressure Sensor, located on the driver’s side of the throttle body, mounted on the same bracket that holds the plastic throttle body cover over the assembly, has two hoses coming out of it.
· EGR Ports – Two Ports in the EGR Manifold that Carbon builds up creating EGR Insufficient flow
After much research and trying to change the DPFE Sensor twice, I concluded that that 90% of the cases researched the EGR ports in the EGR manifold are truly clogged. I mean I spent about an hour with pipe cleaners and Carb cleaner working in the ports, I wished I had a part cleaner tub.
In your research you will read allot about the DPFE Sensor, however, before you spend the extra $60, please take some time and take the throttle body apart and clean the EGR manifold and Ports.
Note also check the hoses on the DPFE Sensor, Mine were split where they connected to the sensor. Not that I think it was associated with the problem. More of a visual resolution.
The whole project took me about 2 hours and costs about $6.00- $2 for carb cleaner, $2 for hand cleaner, and $2 for replacement hoses. Good Luck
Enclosed is the link to a very resourceful website dedicated to cleaning the EGR manifold and Throttle Body components.
throttlebodyclean.php
The only thing that he mentioned wrong is:
· Simply disconnect the fuel injection cable, it simply snaps off of the throttle body spring.
· Take the EGR manifold off of the throttle body, its easier to clean.
· If you are careful you will not need to replace gaskets.
· Throttle body cleaner and Carb cleaner have the same ingredients so I concluded they are the same. Save the Money
Last edited by thomasdbaker; Jul 25, 2005 at 08:26 AM.
Hotshot
Joined: Jan 2004
Posts: 19,762
Likes: 1,079
From: St Louis
Originally Posted by kevin henderson
is the pcv elbow the little 90 on the egr valve or something else
The PCV elbow, ironically, is on the PCV line.
Steve