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Discussion Starter #1
I'll take my car to Auto zone tomorrow but I need your opinions on this too.
I was driving in stop and go traffic today, I turned AC on to see whether system is fine after winter, I smelled coolant for some time. turned the AC off, smell disappeared. Then CEL came on, I didn't see any driveability problems, shifting was normal, temperature gauge was normal, idle speed was normal in drive and park.

First thing came up to my mind was the head gasket failure. I checked the coolant, it was on normal level. It was replaced 2 yeas ago. I was planning to take it to dealer to get it flushed again. What is happening to my G4??
 

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i personally wouldn't screw around and i would get the code read asap! coolant smell problems typically spell some sort of disaster is eminant. thought i would try to lift your spirits just a little. (he says very sarcastically) brian
 
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I agree - get your codes read before you do anything. When you have a code, let us what it is and we can go from there. :)
 

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My Gen4 is a lemon!

I have had 2 Check Engine Lights in the past month! Once it was for the PATS system, and now it is something with a emmisions thing.. *sigh* The warrenty paid for itself altready :D
 

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Discussion Starter #5
The car has P0402 Excessive EGR flow. How the heck this is happening?

I applied some vacum to valve in park idling, the car stalled. So, valve is closed in idle and if the vacum is applied valve is opening. If the valve is opening and closing (spring is respondig to vacum), how the heck excess flow is happening.

What about that coolant smell, I no longer get it. I don't feel good about this issue.

Any idea, past experience...

Thanks guys
 
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Here is what the service CD says:


HE20 DTC P0402: CHECK FOR EGR FLOW AT IDLE WITH EGR VACUUM HOSE DISCONNECTED

NOTE:
If DTC P1405 is in continuous memory, diagnose that first starting with HE50.

l Disconnect vacuum hose at EGR valve and plug hose.

l Run Key On Engine Running (KOER) Self-Test.

l Is KOER DTC P0402 output or unable to run KOER Self-Test due to engine stall or no start?

Yes
KEY OFF. INSPECT pressure hoses first for pinching and icing. If OK, REMOVE and INSPECT the EGR valve and EGR tube for signs of contamination, unusual wear, carbon deposits, binding and other damage. REPAIR as necessary.


No
RECONNECT vacuum hose to EGR valve. GO to «HE21».

If you need more info from the service CD, let me know. Hope this helps. :)
 

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Discussion Starter #7
Jason, thanks for the info. Does your CD have any thing for DFPS?
I am also considering DFPS, since the car stalls when I apply vacum in idle, I think EGR is OK.

I read many postings in archive, many people ended up replacing DFPS, some was talking about a recall for 2000+ tauruses for DFPS, there was no such recall I could find...

Some also talks about cleaning, how do I clean this thing...?
 

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Originally posted by FullDuplex@May 9 2004, 11:11 AM
Jason, thanks for the info. Does your CD have any thing for DFPS?
I am also considering DFPS, since the car stalls when I apply vacum in idle, I think EGR is OK.

I read many postings in archive, many people ended up replacing DFPS, some was talking about a recall for 2000+ tauruses for DFPS, there was no such recall I could find...

Some also talks about cleaning, how do I clean this thing...?
Here is the skinny -

There was never a recall for just the DPFE. Failure of the EGR was so widespread that instead of issuing a recall for all gen 4s, they extended the coverage of the EGR components for an additional 24,000 miles. So 36000 plus 24000 = 60000 miles. If your car has 60000 miles or less, you can take it to a dealer and they will fix it for free.

There you go, good luck.

-Damon
 

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Discussion Starter #9
Is there any thing out here in the Internet to back this one up. I like to go to dealer armed in case if they start bsing me.
Like any TBS, or anything...
Thanks
 

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Originally posted by FullDuplex@May 9 2004, 12:03 PM
Is there any thing out here in the Internet to back this one up. I like to go to dealer armed in case if they start bsing me.
Like any TBS, or anything...
Thanks
The extended coverage for certain 2000 and 2001 Fords covers replacement of the dpfe sensor for an additional 24 months or 24k miles whichever comes first. You can call the local Ford dealer and see if your car is covered under program number 02M01. I got my letter in January of 2003 I think thats when they started the program. If you need some proof you could always google it or maybe try a search over at Flatrate Tech Forums Every time I have seen the P0402 Excessive EGR flow code it has been the dpfe. Oh yeah if you register at myford you can see if you are eligble also.
 

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Discussion Starter #11
I checked with Ford, unfortunately, they ran the VIN and turned out to be my car was not eligable to extended warranty on DPFE.

I also looked for the part number in Google, some people used parts from Autozone. But I like to stick with Motorcraft. Is this part from Motorcraft. If yes then anybody knows the part number?

I reset the PCM to see when CEL will come up again. Over all, this could be the problem for my pinging cause my plugs show no sign of high temperature. We'll see...
 

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If you call a local dealers parts department they will give you the part #. Ask them why the Ford or Motorcraft part is better. I usually use motorcraft parts for most applications but it seems this part is prone to fail no matter where you get it. I think the Ford part is $80 and Autozone a lot cheaper. Both should have the same warranty. BTW in some states like California this part may be covered under their emmissions law 7/70. Some other states have similar coverage. Ask your dealer if its covered in your state, they have to tell you if you ask.
 

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Discussion Starter #13
After spending $88.68, I got my new backpressure sensor. This must be a new generation, outer shell is durable plastic. I attempted to use the same rubber pipes but bigger diameter pipe came short due to new location of bigger diameter outlet on the sensor. Luckly, I got some spare and used that one. Reset the PCM and I'll see tomorrow.

I could have gotten from Internet for $70 + $7.95 but I needed right away, so I think I got good price on it.
 
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