Insuffient EGR Flow

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Mar 22, 2006 | 07:05 PM

yasky69

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Insuffient EGR Flow

Now I've got another code for insuffient flow at the EGR. I put in a new EGR and Tube that runs to the manifold. Is there something else in the equation that I've missed? EGR solenoid or something.
thanks

Mar 22, 2006 | 07:20 PM

bosshoss

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Hey there. You might have the dreaded plugged egr ports, or might be the DPFE sensor, or the vacume solinoid for the egr valve. If you put vacume on the egr valve plug, does the engine stumble or try to stall? at idle. If it does not, the ports might be plugged up. You need to remove the throttle body to intake elbow and clean the ports good. I have not seen many egr valves go bad. What motor do you have , and the miles on it? Good luck

Dave P

Mar 22, 2006 | 07:39 PM

yasky69

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I have the 4.6 8 cyl. it has 217000 miles on it. (and proud). I put a new egr on and did a search and according to what I found there is no vacumm solenoid on it. The only thing I found is a egr positioning solenoid

Mar 22, 2006 | 10:51 PM

wjbv5

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I can almost gaurantee it is clogged ports behind the EGR. It happened on mine and like you I chased the problem and replaced the EGR and the DPFE sensor. Ford says not to clean the throttle body but in this case you have to. When you remove the throttle body from the manifolde you will notice 2 ports directly behind the EGR that go down into the bottom of the throttle body and then go straight up at about a 70 degree angle. It is in that elbow you will find the clog. Hope this helps good luck.

Mar 22, 2006 | 11:19 PM

apowder97

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wjbv5 is exactly right. I had that stupid code for a year finally got around to cleaning the ports cleared the code right up.

Mar 23, 2006 | 04:18 AM

50th ann

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From: Royal Palm Beach, Fl

P0401

I suffered through the same problem with code P0401. You did not say what year. I changed the ERG Valve and the PDFE switch and it did not fix it. 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 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 there 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 clean. 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

Good Luck

Mar 23, 2006 | 06:28 AM

lariat97

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From: North west La

I just had the same problem. Cleaned the ports & fixed it.

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Mar 23, 2006 | 11:49 AM

pwgabor

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From: Augusta, GA

What kind of problems will clogged egr ports cause besides throwing codes and having the check engine light on? Mine has been on for almost a year now.

Mar 23, 2006 | 06:16 PM

#10

yasky69

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How hard is this going to be to clean out. I spoke with someone earlier today and he said I have to take the whole intake off... is this true?

Mar 23, 2006 | 06:18 PM

#11

apowder97

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yes but it's rather simple. I don't believe it took me very long. I know it wasn't hard to do.

Mar 23, 2006 | 06:28 PM

#12

wjbv5

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If you can turn a wrench this should be a pretty easy job. There are 8 bolts total that have to be removed. four hold the throttle body to the manifold and 4 coonect the throttle body to the air intake. the only thing you have to be careful with is the gasket between the manifold and the throttle body. If you do not damage it you should be able to reuse it. I put mine back on 40k ago and have had no problems.

Mar 23, 2006 | 06:51 PM

#13

bosshoss

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Take the throttle body and elbow off together, you dont need to take the lower intake of the motor.

Dave P.

Mar 23, 2006 | 06:56 PM

#14

yasky69

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Ok, I'll try it. I was able to replace that egr and tube that goes to the manifold so this should be fairly simple.

Mar 23, 2006 | 08:22 PM

#15

bosshoss

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I think it is a 8mm bolt that holds the elbow on the intake there will be 4 of them. I recomend a 1/4 drive ratchet, extension, and swivel joint to get the bolts out. Good luck, we know you can do it.