Failed inspection-help

I know this question has been asked before but I'm going to ask it again. We took our 99 windstar to get inspected today and this is why it failed. P0401, P0171 and P0174. Before I start dumping cash into getting this taken care of I wondered if anyone has any insite. Thanks.

P0401 ERG Flow Insufficient
Common causes, clogged EGR ports, DPFE (Differential Pressure FEedback)
NOT common cause, EGR valve.

P0171 Too Lean Bank #1
P0174 Too Lean Bank #2
Common Cause.....Vaccum Leak
NOT common cause any Oxygen sensor

For 1999, there is a TSB to address the vaccum leak. The "Isolator" bolts have a sleeve that breaks down from the oil that is normal in any intake system.......solution....replace the intake manifold bolts.
Also in the TSB for your year is to replace the FRONT valve cover with one that has an improved baffel to reduce the amount of oil that is drawn into the intake through the PCV. The replacement valve cover is not painted black....but is silver.
There is also a reflash (reprogram) of the computer to retard the timing to address the pinging issue that can develop from carbon buildup that could have been caused by accessive oil that may have been drawn into the cylinders due to the poor baffel in the front valve cover.

There is a link to a website that someone very patiently took step-by-step pictures of the complete repair process...and posted them with detailed instructions to address exactly the problem you have. This is a repair that you can have done for you.....or do yourself. If you have the repair done for you.....jot down the TSB number(s) and take them to your dealership.
http://leckemby.net/windstar/windstar01.html

NOTE: This TSB is ONLY for 1999 and newer Windstars. The 1998 and older windstars use a different intake manifold and do not have the valve cover issue.
It is NORMAL for there to be some oil in the intake manifold, even after having this TSB done. The 3.8L engine has a strong PCV system....which does a lot to keep the crankcase clean of a lot of crud.
However, the oil vapors, and EGR gasses combine to create the tar that you see at the EGR ports....and dirt up inside the "cap" on the spray end of the fuel injectors.

I would also recommend a physical cleaning of the spray end of each fuel injectors......as you have things apart to the point that it is not much more work......if the engine has many miles.....there will be a buildup of crud inside the "cap" that is over the spray end of the fuel injector.
I was unable to clean this with fuel system / injector cleaner.
It came right off when I sprayed cleaner up inside the cap over the spray end.....but it requires removal of each fuel injector.
I have pictures of the spray end of a fuel injector in my pictures from my 1996 3.8L......and you can see in 1 picture the 4 very small ports on the spray end of the injector. I had a misfire develop....which I chased for several months.....which ended up being the dirt on the end of the fuel injectors......That was at about 137K miles. Pictures from my '96.....for looking at the fuel injector http://community.webshots.com/album/201931518cScpNK

I had the exact same codes on my 99 (although not at the same time). Wiswind is right on the money.

The 171/174 is often caused by the Isolator bolts/port seals and the TSB does address this issue. Don't assume the O2 sensors are the problem no matter what a parts store suggests. (It could be but most often is not)

P401 is the EGR system. On my vehicle it was the DPFE and this is also a known problem and the DPFE has since been redesigned.

I posted some tests for the DPFE in an earlier post (search under DPFE) and there are a lot of posts addressing the 171/174 codes (search under 171/174, Isolator bolts, lean....).

Keep us updated and we will help you through this.

just wanted to say thanks for the info. I printed out your replies and gave them to our mechanic (who is a close friend). He put his computer on our van and the only code that showed up was the EGR. The other ones were gone. Any other insites or help is greately appreciated.

I did have some other questions though... I was looking into the EGR pressure sensor defect recall, and wondering if that was for the windstar or not. If I can get Ford to pay for this thing to be replaced all the better. The other things are 1: our overdrive doesn't work, is there any thing that is common to this and if I can fix it or not. 2: I need to get the face plate off that holds the radio in I can't seem to get it to budge.

Sorry to be such a bother but you guys are awesome. TIA

I do not know of any recall on the DPFE.
A dealer should be able to tell you of any recalls that are out there for your vehicle by entering your VIN into their computer.
The DPFE is high failure....but not expensive....and it is easy and quick job to replace.

For the overdrive, is the "O/D" light on the shifter lit up?.....if not....does it come on when you press the button on the end of the shifter?
If it is lit.....does it go OFF when you press the button?

If the O/D light is flashing....it is an indication of a failure code for the transmission.

I do not know of any recall on the DPFE.
A dealer should be able to tell you of any recalls that are out there for your vehicle by entering your VIN into their computer.
The DPFE is high failure....but not expensive....and it is easy and quick job to replace.

For the overdrive, is the "O/D" light on the shifter lit up?.....if not....does it come on when you press the button on the end of the shifter?
If it is lit.....does it go OFF when you press the button?

If the O/D light is flashing....it is an indication of a failure code for the transmission.


Thanks for repsonding. The O/D doesn't do anything. No light on the dash and no light on the shifter. When you push the button to turn it on it doesn't do anything. Thanks again. I figured out about the DPFE recall I was talking about it was for 2000 and newer, just an extension of the warranty.

The "transmission control switch" (overdrive cancellation) is fed by fuse #14 in box inside cabin near drivers left foot. If you find the fuse OK, the switch, or wiring, would then be suspect.

Normally, with the "OD off" light off, the OD is active. Pressing the button inputs a toggle circuit ... first, to "OD inactive" (light on) ... next, back to "OD active" (light off).

The "transmission control switch" (overdrive cancellation) is fed by fuse #14 in box inside cabin near drivers left foot. If you find the fuse OK, the switch, or wiring, would then be suspect.

Normally, with the "OD off" light off, the OD is active. Pressing the button inputs a toggle circuit ... first, to "OD inactive" (light on) ... next, back to "OD active" (light off).


Checked the fuse already and it's fine. I'm pretty sure it's not the switch because when we drive the van never switches down into the last gear. It runs with the rpm's on 3 all the time.

Thanks