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#242939 - 09/17/03 07:42 AM ENGINE: SENSORS--code P0402 excessive egr flow
chevrofreak Offline
Member

Registered: 05/31/03
Posts: 124
Loc: Billings, MT
I bought an OBDII code reader because my 96 vic p71 was giving me problems, and the mechanic who tested it couldnt give me a straight answer.

When I checked the codes a few days ago I got codes:

P0401 a generic code for Exhaust Gas Recirculation Flow Insufficient Detected
P0402 a generic code for Gas Recirculation Flow Excessive Detected
P1405 a manufacturer code for Differential Pressure Feedback Sensor Upstream Hose Off Or Plugged

I cleared the codes and drove the car for a while. Right around 25 miles the MIL came on so I stopped and pulled the codes again. Once again I got P0402 "Gas Recirculation Flow Excessive Detected".

Whats puzzling me is the previous code for insufficient flow.

What should I check first? What part might be causing this?



Edited by Liquid (10/08/04 10:13 AM)

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#242940 - 09/17/03 11:43 AM Re: code P0402 excessive egr flow, but thats not all!
sn8kebite Offline
Rookie

Registered: 06/25/03
Posts: 80
How many miles .have you clean egr passages.
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#242941 - 09/17/03 11:53 AM Re: code P0402 excessive egr flow, but thats not all!
chevrofreak Offline
Member

Registered: 05/31/03
Posts: 124
Loc: Billings, MT
it has 105,000 miles. i removed the EGR valve and cleaned it. i inspected the passages and they did not seem to be very dirty at all.

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#242942 - 09/17/03 12:07 PM Re: code P0402 excessive egr flow, but thats not all!
Barongrey Offline
Over the Hill

Registered: 02/05/02
Posts: 1690
Loc: Ridgecrest, CA
? Isn't there a rubber hose behind the throttle body that has been the source of many EGR problems?

I haven't had any trouble with mine (yet) but I seem to recall that the hose can either leak (high EGR) or collapse (low EGR) or BOTH in succession.

Sounds like you're ready for a good tuneup, regardless. I'd take extra time to clean the EGR passages, and I'd be replacing the EGR valve, as it's very cheap anyway.

Hang in there, and when you figure it out, please let us know.
_________________________
1997 P71 with 73K miles - SOLD

Meddle Not In The Affairs Of Dragons, For Thou Art Crunchy And Taste Good With Ketchup!

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#242943 - 09/17/03 12:08 PM Re: code P0402 excessive egr flow, but thats not all!
Big_Black_Vic Offline

Member

Registered: 10/21/02
Posts: 345
Loc: Humble, TX
Chevrofreak,

Your problem is NOT your EGR valve itself. It is the DPF-EGR Sensor or Differential Pressure Feedback Exhaust Gas recirculation sensor. What this sensor does is, it tells the EGR how much to open and close, depending on exhaust flow at mid and wide throttle RPM's. I had this exact same problem with mine, and as a matter of fact, I still do. I get the same codes you do. If I clear them, about 15-30 miles after, the light goes back on. I replaced my DPFE sensor with a Autozone Wells replacement, just to find out it went out about 4K miles after. I suggest you get the reinforced version from your Ford dealer. Yes it might cost more, but it will last longer than the cheaper ones. These sensors go out due to idling vibrations. It is a little aluminum box (about 4"x2") that has ceramic inside of it, and is located right beneath the tranny fluid dipstick tube. You cant miss it. It has 1 electrical connector and 2 exhaust hoses plugged to it. Getting it off it quite a PITA, so try to do it with the engine completely cold, and you might need a swivel and a 8mm wrench(not completely sure). I own a 1997 P71, so this problem is quite common on the 95-97 bodystyles. I still havent fixed mine, and not changing it will not harm your engine, but you will NOT pass inspection. Also, your engine might knock or "ping" slightly upon harsh acceleration, due to hotter combustion chamber temperatures.

If you have any other questions or concerns, PLEASE let me know, and I will do my best to answer them.

Best Regards,

-Fern

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#242944 - 09/17/03 02:17 PM Re: code P0402 excessive egr flow, but thats not all!
chevrofreak Offline
Member

Registered: 05/31/03
Posts: 124
Loc: Billings, MT
I cleaned the EGR valve and tested it and it worked fine, so I'm not worried about it.

My engine knocks quite heavily when I am going up a hill, or when it is at WOT and accelerating hard.

I cleaned my MAF, cleaned and gapped my spark plugs (they looked new) put new Motorcraft wires on, and it has a new air filter.

I will check that DPF-EGR sensor and all the hoses and wires connected to it. How much would a Motorcraft brand sensor cost? I will let you guys know how this goes.

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#242945 - 09/17/03 03:59 PM Re: code P0402 excessive egr flow, but thats not all!
dcooley Offline
Over the Hill

Registered: 07/27/01
Posts: 2572
Loc: SC
If it knocks heavily going up hill, then you are not getting any EGR... that's a very good sign the intake manifold passages are plugged, EGR tube is plugged etc...
_________________________
96 TownCar
97 Dodge Ram 1500 Club Cab
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Mopar Performance 1.6 Roller rockers
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3" Magnaflow Muffler with 3" mandrel bent tailpipe
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#242946 - 09/17/03 10:43 PM Re: code P0402 excessive egr flow, but thats not all!
Big_Black_Vic Offline

Member

Registered: 10/21/02
Posts: 345
Loc: Humble, TX
If memory serves me correct, a new DPFE sensor will cost you around 70-80 bucks at Ford and about 45 at Autozone or O'Rileys.

-Fern

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#242947 - 09/18/03 07:14 PM Re: code P0402 excessive egr flow, but thats not all!
chevrofreak Offline
Member

Registered: 05/31/03
Posts: 124
Loc: Billings, MT
I might just go ahead and get a generic part from the local Bumper To Bumper because they have always replaced parts for me under warranty, including an alternator that blew out due to my car stereo, which was my own fault, and a clutch that I burned out in a matter of months from doing too many burnouts.

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#242948 - 09/19/03 07:02 AM Re: code P0402 excessive egr flow, but thats not all!
chevrofreak Offline
Member

Registered: 05/31/03
Posts: 124
Loc: Billings, MT
Oh and another bit of info. SOmetimes while driving, the check engine light will go out. It doesnt matter if i've been running the hell out of it or just puttering around town, sometimes it just goes off.

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#242949 - 10/08/03 06:58 PM Re: code P0402 excessive egr flow, but thats not all!
chevrofreak Offline
Member

Registered: 05/31/03
Posts: 124
Loc: Billings, MT
Thats what it was, it was the DPF-EGR sensor. I pulled one off a 96 Ford Escort at a junk yard for $15 (extremely easy to remove) and put it on my car. She runs great now and is getting better gas mileage to boot.

Thank you very much.

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