EGR and IMRC
Winny1234
02-08-2008, 06:23 PM
Hi there, I have a 1999 windstar 3.8 liter
I have been having a vibration or shuddering kind of problem which seems like the engine is bogging down, and today i pulled the vacuum from the egr valve and took it for a drive, the van drove great with no bogging down or anything. My question is what do I do now to fix the problem. I put a straw onto the egr valve inlet and sucked to apply a vacuum while the van was running and whenever i sucked the van would try to die indicating the egr valve is good right? I have no check engine lights or anything.
My other problem is the IMRC. I had those plastic bushings break and I never got any check engine lights, so i fixed that and today I disconnected the electrical connector to the black IMRC box and took the van for a drive, the van didnt drive any differently and it didnt set a check engine light. Does my IMRC even work, is there any way to test it?
THANK YOU
I have been having a vibration or shuddering kind of problem which seems like the engine is bogging down, and today i pulled the vacuum from the egr valve and took it for a drive, the van drove great with no bogging down or anything. My question is what do I do now to fix the problem. I put a straw onto the egr valve inlet and sucked to apply a vacuum while the van was running and whenever i sucked the van would try to die indicating the egr valve is good right? I have no check engine lights or anything.
My other problem is the IMRC. I had those plastic bushings break and I never got any check engine lights, so i fixed that and today I disconnected the electrical connector to the black IMRC box and took the van for a drive, the van didnt drive any differently and it didnt set a check engine light. Does my IMRC even work, is there any way to test it?
THANK YOU
wiswind
02-09-2008, 07:05 AM
2 common issues with the EGR system are clogged EGR ports and the EGR flow sensor, aka DPFE.
You have to remove the upper intake manifold to get to the EGR ports in the lower intake manifold, to clean them.
The DPFE is an easy DIY repair also.
Your troubleshooting has indicated that your issue is caused by the EGR system, and it is almost certain that it is 1 of these 2 things......or both (EGR ports / DPFE).
If the EGR ports have not been cleaned.....I would do it anyhow......routine maintenance.
As far as your IMRC, I am not personaly familiar with the electrical version that is used on the 1999 and newer windstar.
The IMRC will not open until your engine RPMs reach a minimum RPM......which I have read may be different for different years.
I would reconnect it.....and....if you are not getting a CEL, don't worry about it.
You have to remove the upper intake manifold to get to the EGR ports in the lower intake manifold, to clean them.
The DPFE is an easy DIY repair also.
Your troubleshooting has indicated that your issue is caused by the EGR system, and it is almost certain that it is 1 of these 2 things......or both (EGR ports / DPFE).
If the EGR ports have not been cleaned.....I would do it anyhow......routine maintenance.
As far as your IMRC, I am not personaly familiar with the electrical version that is used on the 1999 and newer windstar.
The IMRC will not open until your engine RPMs reach a minimum RPM......which I have read may be different for different years.
I would reconnect it.....and....if you are not getting a CEL, don't worry about it.
Andrew1941
02-11-2008, 03:35 PM
I have a 2001 Deathstar and it was doing the same thing you are describing. It would tend to bog down subtly whenever we were driving around 80 to 90 km/h and gently applied the gas. It would pass quickly, but it was noticeable.
I just cleaned out the EGR. The ports were not plugged, but there was a lot of oil in the clamshell and all over the air direction piece inside the top of the manifold. I did notice that the butterfly valves beside the ports were covered in carbon deposits and so I sprayed it all down with carb cleaner and then carefully wiped it down with que-tips. I then opened the butterfly valves and sprayed in past them to make sure everything was clean. While I was there I changed all the bolt grommets and port gaskets etc. I was quite easy following the post for the engine codes "check engine light" which I did have the check engine light on (engine was running lean). The grommets were hardened and I found one loose vacuum hose while removing the EGR manifold.
So far so good, no engine light back on yet (only been one day), but bogging down does not appear to be there anymore. The repair was about $50 CAD (Lordco can get the parts as Amizon will not deliver to Canada anymore) and the work took me about 5 hours, but was pretty easy and I am no mechanic!
I just cleaned out the EGR. The ports were not plugged, but there was a lot of oil in the clamshell and all over the air direction piece inside the top of the manifold. I did notice that the butterfly valves beside the ports were covered in carbon deposits and so I sprayed it all down with carb cleaner and then carefully wiped it down with que-tips. I then opened the butterfly valves and sprayed in past them to make sure everything was clean. While I was there I changed all the bolt grommets and port gaskets etc. I was quite easy following the post for the engine codes "check engine light" which I did have the check engine light on (engine was running lean). The grommets were hardened and I found one loose vacuum hose while removing the EGR manifold.
So far so good, no engine light back on yet (only been one day), but bogging down does not appear to be there anymore. The repair was about $50 CAD (Lordco can get the parts as Amizon will not deliver to Canada anymore) and the work took me about 5 hours, but was pretty easy and I am no mechanic!
Winny1234
02-13-2008, 12:45 PM
Hey Andrew1941
Can you tell me the part numbers of all the things you got from Lordco, because the lordco I deal with does not know the part number of the seals and stuff. I guess you are located in BC too.
Can you tell me the part numbers of all the things you got from Lordco, because the lordco I deal with does not know the part number of the seals and stuff. I guess you are located in BC too.
Andrew1941
02-13-2008, 02:44 PM
Grommets are Felpro #ES72204 approx $10, but can be difficult to locate (I had to wait a week or so to get them and Taylor Automotive didn't even have any in their parts warehouses!). Save the bolts from the manifold and cut off the old grommets and then push back on the new ones. Saves you a bunch of money instead of buying the Ford bolts with grommets for $130!
Complete gasket set is Felpro #MS90812 approx $40. Ford wanted about $75, but you could buy gaskets individually from them, but why wouldn't you just replace them all?
Also, I suggest you get some carb cleaner. When I removed the EGR manifold, I removed the air direction vane/duct and it was covered in oil too AND the butterfly valves down beside the ports were covered in carbon deposits. I sprayed the carb cleaner down in the ports and carefully used cue-tips to clean out around the valves so they would be free to move properly again.
Better ask Lordco to confirm these numbers are good for a 1999 as mine is a 2001.
Complete gasket set is Felpro #MS90812 approx $40. Ford wanted about $75, but you could buy gaskets individually from them, but why wouldn't you just replace them all?
Also, I suggest you get some carb cleaner. When I removed the EGR manifold, I removed the air direction vane/duct and it was covered in oil too AND the butterfly valves down beside the ports were covered in carbon deposits. I sprayed the carb cleaner down in the ports and carefully used cue-tips to clean out around the valves so they would be free to move properly again.
Better ask Lordco to confirm these numbers are good for a 1999 as mine is a 2001.
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