EGR flow insufficience (Windstar)

[lteehq]

I want to purchase a Windstar Sport 2001. Prior to purchase, we made a mechanical inspection and found the code error "EGR Flow insufficience". What is the signification of that code, and what is the role of that EGR ? Is it expensive to repair ?

By the way, I would like to know if a Windstar Sport 2001 is a good choice ?

[wiswind]

You WILL want to get that corrected.

EGR ports are known to clog.....not too bad to clean....but MUST be done if they are clogged. Can lead to more problems (such as engine miss) if not taken care of.... Also....very likely to cause you to fail emissions testing...if you have that in your area. Some areas just look the car over and plug into your OBDII computer plug....and read the codes.....and fail you if you have something like you mentioned. Could be a suprise when you go to register the car.

EGR (Exhaust Gas Recirculation) is a critical emissions system.
Reduces emissions....and also reduces combustion temps under certain curcumstanses.

The computer takes a variety of inputs, such as engine temp., throttle position, and the EGR flow..... and sends a signal to the EGR Vacuum Regulator Solonoid (on my '96...is on the back of the upper intake manifold).....which converts the electrical signal into a vacuum......that travels through a little hose to the EGR valve. The vacuum will open the EGR valve.

EGR flow is measured by the Differential Pressure FEedbak sensor (DPFE).
The DPFE sends an electrical signal back to the computer......If there is NOT flow.....or it cannot get the flow that it should....then a fault code is set......
The DPFE is also known to fail....easy...and not expensive to replace.
Is located next to the EGR valve....there is a pipe going from the front, bottom....exhaust manifold....up to the EGR valve.....and there are 2 small short pipes....with hoses going to the DPFE.

Also...there is a vacuum line that goes to the EGR valve.....make sure that it is not just disconnected.....

Many seemingly complex problems have very simple and easy solutions......that is....once you find it.

Also....the 1999 and newer windstars are in need of a TSB....look around in this windstar forum....and you will find more information.....I have a '96....so the folks with the newer ones can be of more help to you.
Part of the TSB was to replace one of the valve covers due to a problem with the baffel for the PCV.....to reduce oil getting into your intake manifold......new bolts and bushings for the upper intake manifold cover to reduce vacuum leaks....and some other stuff......costs a bit to have done......

Also....The Transmission fluid is supposed to be changed every 30K miles.
If that has not been done.....problems are likely with the tranny.
The Windstar (or pretty much ANY minivan ) is NOT a good vehicle to use for towing any kind of weight. It is a CAR transmission....but....seems that you will find this same issue with any minivan.

ANY car will have it's issues.....so....I do not want to scare you away from the windstar. Windstar owners tend to expect a lot.

[markt52585]

As I posted before. If you change the EGR sensor, make sure you get the newest design. Ford did have major issues with them. Make sure that you get part number: 4U7Z-9J460-AA from Ford. This time Ford is actually cheaper than AutoZone. Cost is about $35.00. I do love my 2001 Windstar Sport. The only thing I have ever had problems with was the bad EGR sensor that I replaced for $35.

[Rowdysrides]

I was amazed, actually bought all my sensors at a Ford dealer, which was comparable or cheaper than our local Napa.

[DRW1000]

The sensor is the DPFE. They are known to fail and the new style has a black plastic case compared to the old alumunium case.

[adopted-bassist]

I just put my Chrysler Intrepid through the E-Test and it almost failed the fuel economy portion. I have a faulty EGR and the system is trying to compensate as a result my mileage has gone way down...this is another reason for a properly operating EGR.