'99 Windstar 3.8L

[Gobbler865]

Ok. NOW I'm frustrated. Got the P0171/P0174 (Lean mix Bank1/2). Changed the DPFE, EGR, Pulled the plenum and cleaned the Ports 1st ports on L and R side furthest from the throttle body were fairly plugged. Did what I thought was a good thruough cleaning and even cleaned all the residual oil inside the intake manifold. I changed the O2 sensors on the front below the radiator and down around the convertor. I just don't know where to go from here. I believe all my vaccuum lines are intact and without leaks. I even changed the MAF earlier in the year.

What next. Any idears??

[12Ounce]

Did you change out the bolts and seals?

[Gobbler865]

No, I didn't bother changing out the bolts and seals as they don't appear to be leaking. The bolts were tight (I checked). I didn't want to go buck wild and go replacing the bolts and seals unless I REALLY had to (more time out working on the money pit on wheels than I had!!). Any other ideas. OH, one more thing, the van only surges and wants to stall when it goes from a cold start to warming up, Just as the temp gauge moves off the COLD area, abotu a 1/3rd up the gauge. When I do warm starts or restarts, it NEVER surges, since I have done all the work. Does this shed any light on things?

OK, NOW I feel foolish! I just searched under "rough idle when cold" and got the explaination I needed. It's not so much the EGR ports or leaks in the lines, but the isolator bolts are leaking air from the outside into the intake when cold and warming up. The explaination (and I'm sorry I cannot recall who explained it) jist was that when you first start up, it's a rich gas mix with high idle (surging not noticable). When it's all warmed up, everything expands and no air gets in around the bolt shoulders. It's when the engine is starting to get warm that not everything has expanded at the same rate and with the degredation of the isolator bolts "rubber", air is seeping in after the MAF and the computer is trying to accomodate this extra air intake. This is what is resulting in surging, rough idling, and the lean codes popping up on me.

DOH!!! I feel upid!

[Gobbler865]

Okay. Did the TSB update. Now I got a P0401 *EGR Insufficient Flow* code. I already changed out the DPFE and EGR valves and cleaned the EGR ports while doing the TSB update. I *think* I replaced all the vaccum lines I pulled earlier today. Any other suggestions? I never did pull the DPFE lines off the vapor pipe. Should I pull these just in case they are clogged as well? Just wondering. BTW, the CEL didn't come on until about 100 miles driving today.

Mike

[12Ounce]

Originally Posted by Gobbler865

Okay. Did the TSB update. Are you saying the isolator bolts have now been renewed?? Now I got a P0401 *EGR Insufficient Flow* code. How is it running ... still chugging/jerking??I already changed out the DPFE (Sensor? Regulator??) and EGR valves and cleaned the EGR ports while doing the TSB update. I *think* I replaced all the vaccum lines I pulled earlier today. Any other suggestions? I never did pull the DPFE lines off the vapor pipe. Should I pull these just in case they are clogged as well? I would remove and inspect the EGR sample hoses ... they may be plugged or they may be old and split.Just wondering. BTW, the CEL didn't come on until about 100 miles driving today.

Mike

Good luck ...

[Gobbler865]

Like a few other folks on here...I figured it out AFTER I posted . I taped and labelled all my vaccum lines and other things I pulled off 1 thru 7, with some help from my 6 year old daughter. So, I went outside to look on the backside of the intake and low and behold, I found some tape...#6 (the vaccum line above the #4 intake), found the line and married them. Viola! Oh, BTW, from walking outside to clean up, 2 hrs for the seals and bolts.

[12Ounce]

Good work !! Nothing like having a good helper!