EGR ports cleaning

[catvents]

Is it possible, for a 2001 Windstar, to clean the 6 EGR ports in the upper intake, in removing just the plenum. The van has a little bit more than 150k miles, never shown the PO171/174, but intermitent PO401; I have replaced the DPFE ( the older one was ever an upgrade) and also the EGR solenoid but without result. Before doing the complete job I would like to see if can cure the problem in just cleaning the ports.

[wiswind]

You remove the upper intake manifold, and the ports are right there....in the lower intake manifold....right next to the air passage for each cylinder....that does not have the IMR "butterfly".
I have pictures posted of what they look like on my '96 3.8L.
Your 2001 will be similar.
A small sharp object and a shop vac. will do the job.
The junk is ONLY right at the end of the port....where it meets the main airflow....so you don't have to worry about cleaning on down into the passages.
Try to avoid as much as possible getting anything on down into the intake.

As a note, fuel system cleaners will not clean the EGR ports because the fuel does not touch this location.
Cleaners sprayed into the air intake will do practically nothing to clean them either.

[catvents]

Originally Posted by wiswind

You remove the upper intake manifold, and the ports are right there....in the lower intake manifold....right next to the air passage for each cylinder....that does not have the IMR "butterfly".
I have pictures posted of what they look like on my '96 3.8L.
Your 2001 will be similar.
A small sharp object and a shop vac. will do the job.
The junk is ONLY right at the end of the port....where it meets the main airflow....so you don't have to worry about cleaning on down into the passages.
Try to avoid as much as possible getting anything on down into the intake.

As a note, fuel system cleaners will not clean the EGR ports because the fuel does not touch this location.
Cleaners sprayed into the air intake will do practically nothing to clean them either.

Yes I have tried Berryman few times but without result too. I will go as per your recommandations and clean the ports, this should probably cure this problems; will let you know.
Thank you

[Dan_J]

Cleaning the ports made a world of difference in my 98 and cleared the CELs. Good luck!

[catvents]

Originally Posted by wiswind

You remove the upper intake manifold, and the ports are right there....in the lower intake manifold....right next to the air passage for each cylinder....that does not have the IMR "butterfly".
I have pictures posted of what they look like on my '96 3.8L.
Your 2001 will be similar.
A small sharp object and a shop vac. will do the job.
The junk is ONLY right at the end of the port....where it meets the main airflow....so you don't have to worry about cleaning on down into the passages.
Try to avoid as much as possible getting anything on down into the intake.

As a note, fuel system cleaners will not clean the EGR ports because the fuel does not touch this location.
Cleaners sprayed into the air intake will do practically nothing to clean them either.

OK I did it. A quick job if I can say but not a complete job.
2 EGR ports was totally clogged, 2 other almost clogged and the other one not so bad. The intake and the plenum was very oily, ( I have cleaned them)
Since 1 year I was driving with an aftermarket PCV valve and I supect that for the oil in the plenum/intake so I have just install a Motorcraft valve. The isolator bolts are the black one so I will have to replace them.
The CEL in now off ( I have erased with my OBD II tool) and no PO401 is back.