egr valve

diehardnyy · 03-29-2007, 10:37 AM

My windstar runs fine for days maybe even a week or so.Then for no ryme or reason it will run rough and stall either when backing up,or pulling out from a dead stop the engine is warmed up.I will start it up again and it will run fine for a while then it will do it again.
A possible related annomily noticed when my mechanic was looking for the problem:the EGR vaccume hose is disconnected and plugged.Whet it is connected to the EGR valve the car runs horrible and stalls.EGR valve checks good.

Afrodeziak · 04-01-2007, 09:05 PM

I have the same issue ? I have always wondered if it was a vaccum leak, also this egr area ?

sfd4 · 04-03-2007, 06:18 PM

I have had the same problems when temperatures are below 35. any ideas on problem

philkb · 10-27-2007, 02:57 PM

You may have a defective EGR control solenoid. take the "plug" out of the EGR vacuum hose and see if you can feel suction on it when the engine is running, or else get a vacuum gauge to check it. There should be no vacuum when at idle, only should be vacuum when cracking open throttle. At high throttle openings there also should be no vacuum although you would only be able to check that while actually driving, which would be difficult to do without a long hose and an assistant.

RickMN · 10-27-2007, 08:28 PM

Here's a great article on the Ford EGR system and how it works.

FORD EGR

homedepot · 12-03-2007, 01:44 PM

I had a similar problem and it turned out to be the EGR sensor. It seems that the EGR valve can get stuck open for no reason and send gases at such high temperatures that it actually melted the hose plug legs out of the sensor. When this happened (I swear) the hose felt backwards pointing at the lower manifold only an inch away. These made a hole in the lower manifold about the size of a nickel. I made it to the house riding a yound bronco of a windstar. Went to a mechanic (not technitian) and he spotted the problem in 30 seconds. His solution was going to cost me about $425 plus labor but I solved it with 50 cents worth of epoxy putty and some intake-system-safe silicone. Replaced the EGR sensor and it ran perfect. A year later it damaged the sensor again. Replaced it and its been running well since.

If your EGR valve stays open, there is nothing to do but replace it. When you do, replace the sensor as well.

My 2 cents.

Alex.

Flyingjackal456 · 12-03-2007, 04:41 PM

The EDR valve itself rarely goes bad, replace the sensor before you replace the valve. I'd also check the vacuum as philkb said.

Good luck Diehardnyy!