2004 Taurus Duratec Question - Taurus Car Club of America : Ford Taurus Forum
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  • 2 Post By chartmaker
  • 1 Post By Jeff K
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post #1 of 9 (permalink) Old 03-25-2019, 02:17 PM Thread Starter
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2004 Taurus Duratec Question

Hello all. I need some advise. I replaced the 3 cats and exhaust system. The car is running fine. I can get to 85 mph no problem. But the check engine light came on P0406. EGR sensor is high.


I looked at the EGR Valve but there is only a vacuum hose attached and it looks fine. Looks to be the original one. I have 245,000 miles on the car. How can I test it?



Thank you.
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post #2 of 9 (permalink) Old 03-26-2019, 06:04 AM Thread Starter
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Thank you Sheila.
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post #3 of 9 (permalink) Old 03-26-2019, 07:19 AM
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Quote:
Originally Posted by sleeperph View Post
Hello all. I need some advise. I replaced the 3 cats and exhaust system. The car is running fine. I can get to 85 mph no problem. But the check engine light came on P0406. EGR sensor is high.


I looked at the EGR Valve but there is only a vacuum hose attached and it looks fine. Looks to be the original one. I have 245,000 miles on the car. How can I test it?



Thank you.
I would look at the DPFE, pic for one of two kinds, depends on your car year. If you had a plugged cat it could have put undue pressure on this unit.


I had '01 that would set a code from time to time. I replaced the EGR valve, made no difference. Got a JY DPFE, and no more issues.


-chart-
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post #4 of 9 (permalink) Old 03-26-2019, 07:22 AM
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^^^^^ +1000
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05 Taurus SEL Duratec - my daily driver
04 Taurus SES Duratec - wifes car - TOTALED
06 Taurus SE Vulcan - wifes new ride
95 Taurus GL Vulcan winter car
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post #5 of 9 (permalink) Old 03-26-2019, 11:45 AM
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^ sleeperph, disregard my post above which I deleted to avoid spreading bad advice. I had a "senior moment" reading egr as pcv, lol! Chart's and Jeff's advice to replace the dpfe (egr pressure sensor) and it's hoses is spot on! If not the dpfe sensor, may check the evr. Motorcraft egr valves are nearly bulletproof. They may get dirty/carboned, but can be cleaned. On the other hand, pcv valve/hose should be checked/replaced ea. 80-100k mi. if not sooner.
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Last edited by sheila; 03-27-2019 at 11:40 AM.
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post #6 of 9 (permalink) Old 03-29-2019, 08:26 AM
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Take a can of carb cleaner and spray around the EGR with the car running....If the the idel goes up , then you have a leak and have to replace it.
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post #7 of 9 (permalink) Old 03-29-2019, 10:18 AM
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You can also perform the simple egr "suck" test. With the engine idling, remove the egr vacuum hose and replace it with a ~12" scrap piece of rubber vacuum hose. Suck on the open end of the sample hose opening the pintle allowing egr flow. Engine should stumble or die. This is due to the fact that there should be no egr flow at idle or wot. If eng. fails to stumble or die, clean egr valve and its passageways.
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Last edited by sheila; 03-29-2019 at 11:34 AM.
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post #8 of 9 (permalink) Old 06-05-2019, 08:07 AM Thread Starter
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Hello all, thank you for the replies. Sheila, I do have a Vacuum pump and did the EGR test and that was not the issue. Chartmaker was on track. I had replaced the DPFE too so did not think that was the issue. I found that the DPFE connector wires had melted so I purchased a DPFE sensor connector (2U2Z14S411AA). Now the issue is that the new connector has 3 wires but they are all grey in color. Since the wires melted I was looking for a wiring diagram that shows where the 3 wires go but have not been able to find one. Does anyone have information on where the 3 wires go? I have a 1 in 6 chance of getting it right by guessing. Thank you.
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post #9 of 9 (permalink) Old 06-19-2019, 09:52 PM Thread Starter
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UPDATE:
We replaced the DPFE Sensor Connector. We cleared the codes. Only the P1000 drive cycle was left I drove the car about 200 miles and the P1000 cleared. Took it to inspection and passed the NJ emissions test. Now inspected to 2021. Tomorrow will break 248,000 miles. Round trip to an from work is 75 daily. Bought the car with 14000 miles on it in 2005. Hopefully I will be able to get a few more years out of it.
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