I have a 2002 Ford F-150 4.6L V8. My check engine light has been on for a little while and I decided to bring it to the dealership to get checked out.

My truck has been running fine with no noticeable problems. Ford dealership told me that 4 of my 8 coils were bad and wanted to charge me over $1000 to fix. I did not get the repair done and brought it to Autozone several days later. Using a diagnostic computer they ran the codes and came up with "EGR flow insufficient". This was the only code that appeared. After reading several of these helpful forums it appeared my DPFE sensor may need to be replaced. I looked at my engine and could not locate the DPFE sensor where it was supposed to be. I have looked at many diagrams and repair manuals and still can not locate it. Is it possible that the sensor has been removed? Do you think the coils are bad? Any help would be appreciated because I dont feel like spending $1000 on something I dont need.

 

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Going from memory, the DPFE sensor kinda' floats on the driver side above the intake manifold and in front of the firewall. It has two vacuum hoses going into it and they could very easily have been changed or shifted.

Before you replace the DPFE sensor, be sure that all vacuum hoses are unbroken and connected. I have a 2001 4.6 and had that same DTC. I replaced the Dpfe sensor and still had it. I found a broken vacuum hose. There is a red and a green hard plastic vacuum hose that go into the intake tube. I had to fabricate a connection with rubber tubing and that solved the problem. When I have the time, I may get a new piece from Ford.

If that isn't your problem, I would next consider cleaning the EGR passages in the throttle body, particularly if you have over 75,000 miles, use an aftermarket air filter, or idle a lot. That's cheaper than the DPFE, although it IS more work.

Incidentally, I don't believe insufficient EGR flow will ever case you any noticeable problems, however, you will not be able to pass any emission tests that you may be subject to.

When you get that solved, if your SES light comes on again indicating a misfire, you can pin it down to the particular cylinder (s) and replace only that coil. I would recommend you get Motorcraft (because these have been a weak point and Motorcraft is most likely to have improved them). I bought two at Murray's recently for ~ $60 each. In my experience, the SES WILL come on if you have a problem. Otherwise, it is like changing a light bulb because somebody thinks it's nearing the end of its life.

 

LOOK FOR THE 9J460

 

Thank you for your reply.....my truck has 43,000 miles on it and I just recently changed to a K & N Air Filter (after the check engine light came on). I still have yet to notice any problems with my truck. I was just wondering where the Ford Dealership got "4 of 8 coils are bad". I have never had a misfire, loss of power, or decrease in fuel efficiency. About the DPFE sensor.....i looked extensively on the drivers side near the cab of the truck and could not locate it. If I can I will take a picture of where it is supposed to be. Thanks again for the help.

 

The DPFE sensor is item 9J460 in the above diagram.

Maybe that dealership tech had a boat payment due....and picked you to make it for him.

Steve

 

The DPFE is on the driver's side of the intake under the plastic cover. Might as well pull the throttle body and elbow from the rest of the intake and clean the EGR ports before you shell out the $65 for the DPFE. If you're careful and don't destroy the gaskets, you may fix it for free. Worst case......you rip the gasket and spend 6 bucks for a new one. Chances are, you need to do this even if the DPFE is bad.

 

Here is a picture of my engine.....i know its a little hard to see but I circled where I think the DPFE sensor should be located. Any help is appreciated to let me know if I am looking in the wrong spot.

http://quick.imgfree.net/61837

 

THAT IS WHERE IT SHOULD BE! looks like it not there!!

Ed

 

The other problem I have is all the connections to the DPFE seem to be missing too. Could it somehow be rerouted in the engine to pass over the DPFE sensor?

 

Look at the tube that connects your EGR valve to the exhaust manifold. There are two long nipples extending from it. The DPFE should be connected to these nipples via flexiple rubber hoses.