Cleaning Egr Ports

Working On 96' Windstar 3.8 80,000 Miles.dealing With Intermitend Random Misfire,codes 300,301,304.replaced Plugs(although All Were Like New),replaced Plug Wires(one Weak),have Heard That A Blocked Egr Port Was Extremely Common On This Model.if So Is There An Easy Way To Clean The Egr Port?if Intake Manifold Must Be Pulled ,are There Any Tricks Or Special Things To Watch Out For? Any Advise Will Be Appreciated.

I recently fixed misfires on my 98 (with 102Kmiles) by cleaning the clogged EGR ports. I am absolutely amazed at how well the van now runs. It's like brand new...no kidding!!! Kinda wish I did the repair last year when I first noticed the hesitation/miss.

It's was quite a simple procedure and only requires removing the "upper intake plenum"...not the lower intake. All gaskets (in my case) were re-usable since they were rubber. You'll want to remove the 2pc plastic windshield wiper cowl for access. There are some "butterfly" looking valves in the lower intake that were all gummed up. Used lots of carb cleaner on a rag and cleaned them up until they were spotless. They will operate very smooth when you're done.

It will be obvious which EGR ports are clogged, and as others say, the ports closest to the EGR clog first. I held my shop vac to the EGR valve mating surface while I poked through and brushed the 6 egr ports. This helps keep all the carbon from going airborn and into my lungs. A small circular brush and compressed air also was useful.

Good luck on your repair!!! -lord kelvin

I have cleaned the EGR ports on my '96 3.8L.
I took pictures....and have them posted at....

http://community.webshots.com/album/201931518cScpNK

You will want to be careful to avoid getting crud on down into the lower intake manifold.....as it will then go into the cylinders.....

Another thing that can cause misfire...is crud on the spray end of the fuel injectors. I had to remove each one....and spray cleaner onto the spray end of each injector....the crud came right off. I have pictures of that also in my pics.

You have to remove the upper intake manifold to remove the injectors.
You release the pressure from the fuel system at the needle valve that is located at the center of the front fuel rail. I did not have to disconnect the fuel rail from the rest of the fuel system......I was able to lift if off the injectors (remember to release the clip for each injector) and set it aside.

It’s really a quite simple procedure. I’m not a mechanic and have never done any thing like this before but I cleaned the EGR ports on my ‘96 3.8L Windstar last month.

I had my tools, rags, can of carburetor cleaner, wire from a coat hanger cut about 6 inches long, and a Haynes manual. It took me about 2 1/2 hours to take everything apart, clean, and put back together. I had three that were completely clogged but I went ahead and made sure all six were clean.

We had been having an issue with a misfire on #4, had previously had a complete tune up done, had to replace the catalytic converter but still had the #4 misfire. Thanks to this forum and the great help of some of the regulars here I was advised to check the EGR ports, now that I have cleaned them the van runs great and I have not had any more issues with the misfires.

To All Of You Who Took Time Out Of Your Busy Schedules To Help Me With Information On This Nerve Racking Problem,thank You.this Is By Far The Best Forum I Have Been On .if Everyone Took The Effort To Describe How They Tackled The Problems We Windstar Owners Run Into On A Regular Basis These Vehicles Wouldn't Have The Bad Reputation I Have Read About Since I Started Working On Mine .because When They're Good They're Really Good.

To All Of You Who Took Time Out Of Your Busy Schedules To Help Me With Information On This Nerve Racking Problem,thank You.

Hey I just wanted to pass along my words of encouragement. After completing my job and knowing how much money I saved from not having to take it to a mechanic I would recommend anyone, if they feel comfortable enough, to do some of the minor work that can be done at home. My wife’s brother is a mechanic, in another state, and he said the shop he works at would have at least charged $150 to do what I did. Only cost me about $6 for the can of carburetor and the small bag of rags, of course there was the initial investment of tools that I bought but that has already paid for itself with this first job.

this Is By Far The Best Forum I Have Been On .

I have found it to be really informative and there are a lot of helpful people here.

if Everyone Took The Effort To Describe How They Tackled The Problems We Windstar Owners Run Into On A Regular Basis These Vehicles Wouldn't Have The Bad Reputation I Have Read About Since I Started Working On Mine .because When They're Good They're Really Good.

It does appear that the Windstars have some strange little quirks, but then again every vehicle has it’s quirks too.