One Issue or Two ???

OK, so this morning I was "volunteered" for repairing my sister's '02 Windstar and was only told a few things about it. BUT, they were left under the impression from the shop that looked at it last that they are both the same issue. I'm not so convinced after reading the boards.

First Issue: SES light is on in the dash, was told its the EGR valve setting the code


Second Issue: Van has no heat. Starts to warm up but doesn't after a bit.

I'm thinking the chugging and not wanting to run is part( or all) of the EGR valve. But I'm thinking the no heat is the heater blend door because she is one of those that only knows how to turn the temp slider to one extreme or the other.

It will be sometime this afternoon before I get a chance to do anything further with it at all. But if anyone can give me an idea or a head's up as to it all, I would appreciate the info greatly. These forums have always been a great source of accurate information and always dead on.

If you are in the USA, you can get your engine codes read at many auto part stores for FREE.
Make SURE to get the actual numeric code from them.
P0401 etc.

The EGR valve is not a common failure on the windstar.
However, the DPFE is a high failure item.
The DPFE senses the flow through the EGR system....and this feedback is sent to the computer....which adjusts the EGR valve to get the desired flow.

Another high failure issue for the EGR system is clogged EGR ports in the lower intake manifold.
You have to remove the upper intake manifold to get to the EGR ports.....there is one for each cylinder.....a small 1/4" port by each main air passage.

The pictures that the link in my signature takes you to show the EGR ports in the first few pictures......mine is a '96, so the upper intake manifold is significanly different for yours.
HOWEVER.....THIS is a much better link for your vehicle...and will show you what you need to see in regard to the EGR system.
http://leckemby.net/windstar/windstar01.html

One test that you can do to verify that the rough running is the EGR system......remove and plug the vaccum line that goes to the top of the EGR valve.....take the vehicle for a drive.......
If the vehicle STILL gives the problem.....then it is not the EGR system.
If the problem goes away....then the problem is the EGR system.
NOW.....this WILL set the SEL and set a code for "insufficient EGR flow" as you have disabled the EGR valve from working.
Of course.....this test will not eliminate a sticking EGR valve from the equation....but on the Windstar......that is super rare.

The heat issue is likely the "blend door".
There are a few posts on here that cover that......
An electric motor drives the blend door to determine how much air travels over the hot heater core.

when you say, "starts to warm up but doesn't after a bit" do you mean the heat coming out of the vents or the temperature of the engine? In other words, are you saying that the van doesn't reach the temperature between H and C?

if it is this, then I suspect that you have a bad thermostat that is staying on and thus never letting the engine warm up properly.

If it is at the middle between H and C, then it could very well be your blend door actuator (the motor that turns it) although it would make a clicking sound when you put it in either extreme.

please clarify.

I replaced the thermostat and gasket(have the scars to prove that) last week. The last time I drove the vehicle very far the temp gauge showed the engine was warming up properly. It sounds to me like the blend door. Still haven't made it out to work on the vehicle(garage is full, so working on it outside in teens temps) but I almost have the garage to the point that I can get the van inside. I will pop outside after a bit to listen for the door. Looking at the forecast I'm thinking it is a prime day to catch up on laundry and all.

Just to follow up the solution to the issues ....

Check engine light was the DPFE(EGR Pressure Valve) and not the EGR Valve as originally told. And the DPFE on this vehicle was actually in front of the EGR Valve on the steel pipe, not in the intake area as previously mentioned. I will post pic later on

The lack of interior heat despite the engine coming up to operating temp wound up being the $50 blend door actuator motor that had stripped gears inside.

If anyone wants more information on either of these repairs let me know and I'll go into more detail and with more thoroughness at that point.