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CEL on with code P1405

P

pacific_voyager

Be Gentle I'm New Here
Joined
Oct 11, 2006
Messages
4
I have a '96 2.5L with only 60,000 mile on it. The first symptom was a whistling/buzzing noise from below the egr valve then the CEL came on the following day. Found that both DPFE hoses have holes in them. So the question is how do I replace them. From below the engine, I can see the pipe where the upstream hose connects but I can't see where the downstream hose connects to the pipe. I had to remove a couple of hoses just to see the problem with the hoses but I can't even reach them. I am guessing that the egr valve has to come out but what else? BTW, these two hoses seem to be rubber so it makes no sense to me that they can handle the hot gasses from the exhaust. A month ago I had a code of P1518 and found the secondary throttle valve linkage disconnected. Apparently due to the plastic retainers disentergrating. After I fix this problem, I'll be looking to buy a new car! Thanks for any help you all can provide.
 
Both problems will be much easier to fix by removing the Upper Intake manifold. Not a difficult job. If you were plaining to keep the car,( I know you aren't) I would recommend cleaning the lower intake manifold butterflies, of the carbon that cakes up on them, at the same time. Also would be a good time to check the condition of the insulation on the under hood wiring at the same time, this is a major problem with this year car.
 
pacific_voyager said:
... So the question is how do I replace them. From below the engine, I can see the pipe where the upstream hose connects but I can't see where the downstream hose connects to the pipe. ....
Click to expand...
Welcome :) . Both hoses connect from the DPFE sensor to the EGR tube (near the Bank 1 precat). Haynes has a good picture of it.
 
Ok, thanks for the replies... been out of town since Wednesday. I'm not sure that I have the expertise to tackle removing the intake manifold but I have the Haynes manual and skimmed over the removal procedures and who knows, if I get desperate enough, I might take the plunge. Tony, can you specify the illustration that shows the dpfe connections to the egr tube. I see the "6.22 Remove the EGR tube nut..." photo but that does not help me a lot.
And BTW thanks for the welcome. I think these DIY forums are great and have a great deal of respect for people who are willing to get their hands dirty and try to be self reliant.
 
I forgot to mention that I did have the recall 99M03-R/R wiring harnesses procedure done by the Ford dealer about 3 yrs. ago. It took 2 weeks to complete... too bad they didn't replace all the rubber hoses in the process!!:confused:
 
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pacific_voyager said:
Ok, thanks for the replies... been out of town since Wednesday. I'm not sure that I have the expertise to tackle removing the intake manifold but I have the Haynes manual and skimmed over the removal procedures and who knows, if I get desperate enough, I might take the plunge. Tony, can you specify the illustration that shows the dpfe connections to the egr tube. I see the "6.22 Remove the EGR tube nut..." photo but that does not help me a lot.
And BTW thanks for the welcome. I think these DIY forums are great and have a great deal of respect for people who are willing to get their hands dirty and try to be self reliant.
Click to expand...
Haynes Chapter 2 Figures 6.25, 9.14b.

Also read this Autozone link.
http://www.autozone.com/servlet/UiB..._us/0900823d/80/1b/ca/1e/0900823d801bca1e.jsp

Post by JoeM has picture of one DPFE tube to EGR tube.
http://www.contour.org/ceg-vb/showthread.php?t=3395&page=2
 
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Hoses replaced!

Hoses replaced!

:eek: Ok, thanks for the additional info. I found the upstream and downstream pipes that the hoses from the DPFE connect to by first disconnecting two, about 3/4" OD vacuum hoses that are in the way. Then reaching down with my left hand (it helps to have a skinny forearm) and following the EGR tube with my fingers down to the pressure differential measuring point was able to feel both upstream and downstream nipples. Connected the two hoses by feel only and then the DPFE end connection was fairly easy. I still don't understand how rubber hoses can take the hot exhaust gasses but as I mentioned before, I will be trading this car in very shortly!
I'm glad I did not have to take the intake manifold off because in the end I would probably have to have it towed to the shop. :laugh:
 
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