erg flow insufficient 2001 ford windstar

[csimione]

I have 2001 ford windstar 100,000 miles:
replaced dfpe sensor,
replaced control solonoide mounted directly behind mainfold
cleaned egr ports after removing manifold
reset check engine light
hoses apear to be all connected

Symtoms:
oil in manifold (from PCV valve)
erg flow insufficient code
engine will run rough sometimes when cold when decelerating (rarely happens)

Any help appreciated thanks! 1st time user so bear with me

[northern piper]

what was the CEL code?

[car17fan]

did you try cleaning out the egr valve itself? Carbon gets built up in there and the pintle does not move freely. Also check the vaccuum line to the egr valve to make sure there is enough suction to open the valve.

[csimione]

the check engine code was:
EGR flow insufficient (P401 or something along that line I cant remember the exact # ) but the error did read egr flow insufficient.

The egr valve comes apart? how would I go about cleaning that?

There is a vaccuum on the line to the egr valve, I dont have any way of telling how much.
Is the root of this problem the oil getting up into the manifold via egr valve or is this cause of having something else wrong. Thanks!!!

[northern piper]

was the new dpfe aluminum or black plastic? I know that the aluminum ones are really prone to problems and apparently the black plastic ones less so. I know some auto parts places were still selling the aluminum ones so maybe the one you got was bad?

I'd also really check the vac lines to the egr and dpfe. A small crack can cause lotsa probs.

Piper

[wiswind]

The 2 most common causes of that code are the DPFE (measures the EGR flow, sending a signal to the computer), and clogged EGR ports in the lower intake manifold.

The EGR valve on the windstar seems to be quite reliable.....
Of course.....double check the vaccum line that goes to the EGR valve to make sure that it is connected and in good shape.
Look around for any vaccum lines that might be disconnected.

[Andrew1941]

01 Windstar with the same code. On mine it was the DPFE sensor. Tested it by removing the cowel to get access to the vacuum line for the interior controls. At the surge box on the passender side (which is under the cowel) is a small plastic line which you can disconnect. Move it over to the EGR vavlve vacuum line where it connects to the solendoid (do not attach yet). Set up a voltage meter and measure the DC volts from the wires from the DPFE sensor with the vehicle running. It should be under 5 V. Keep measuring the voltage and have someone push together the two vacuum lines so that you get full vacuum on the EGR valve. The van should stall meaning you open the valve up and choked the engine with exhaust (not enough oxygen in the mix). At the same time, the DPFE voltage should have been changing as the vacuum was applied. This is the sensor telling the computer that the flow through the EGR system is changing. If the voltage doesn't change, then the DPFE is not working. If the van does not stall, then the EGR valve is not working. Is it because the valve is stuck or because the tubing to the valve is plugged. Easy enough to tell by removing the tubing at both ends and see if you can blow through it (yum yum). If the hose is clear, probably need to clean (not sure if you can) the valve or replace the valve. If the valve and the sensor work fine, then I would remove the manifold cover and look for clogged EGR ports. I supose another easy check is to make sure the PCV valve not stuck closed and or the hose is plugged. Valve is only about $10 from Ford, if you have never replaced it, then just replace it, but check the hoses.