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2000 Taurus SES 12v
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821 Posts
So was replacing intake manifold gaskets and hit the EGR tube coming off the exhaust and it snapped (insert curse words and the throwing of the wrench)
Note that the EGR tube is connecting two points that are "mechanically far apart": exhaust, exhaust manifold, cylinder head, lower intake, upper intake, EGR valve. Any change in these connections (caused by changing gaskets) leads to a different distance (exhaust -> EGR valve) to overcome, even though these points seem close together. This means that if you do not loosen the nuts on the pipe, an invisible but very large tension might built up in the tube, and it breaks. That is how I broke mine. My guess is this is what happened. You hitting the EGR pipe was the straw that broke the camel's back.

So when installing the upper intake, you have to use up all the play that you have (the two nuts on the pipe, the two bolts on the EGR valve and the long ones on the intake) and step-by-step tighten them. Now that the EGR pipe is broken, you have to loosen the bolts anyway. The one at the exhaust is somewhat difficult, but with the upper intake off, an adjustable wrench on the nut and a steel bar between the wrench handle and the engine block will do it.
 

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2000 Taurus SES 12v
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821 Posts
The DPFE code is of course the immediate consequence of the EGR pipe being broken, but the others are not immediately obvious.

Worst case, the (very hot) exhaust gasses coming out of the broken EGR pipe ruined some wiring, so you might have to check whether something melted.
 
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