P0401 - Insufficient EGR Flow
EGR stands for Exhaust Gas Recirculation. It is part of the vehicle emmissions system, and is used to reduce combustion temperature and pressure to control Oxides of Nitrogen. There are generally three parts to the EGR system: the EGR valve, an actuator solenoid, and a differential pressure sensor EGR (DPFE). These things work together to deliver the correct amount of recirculation based on engine temperature, load, etc. The P0401 code means that OBD detected an insufficient amount of EGR.
Symptoms: You may notice drivability problems such as pinging (a.k.a. pre-ignition knock) when the engine is under load or the vehicle is at higher speeds. There may also be other symptoms.
Causes: A code P0401 most likely means one or more of the following has happened:
The DPFE (differential pressure feedback EGR) sensor is faulty and needs to be replaced
There is a blockage in the EGR (tube), most likely carbon buildup
The EGR valve is faulty
The EGR valve may not be opening due to a lack of vaccuum
Possible Solutions: In fixing this code, it is quite common for people to just replace the EGR valve only to have the OBD code return. The EGR valve is not always the culprit:
Use a vacuum pump and pull the EGR valve open while monitoring engine RPM's & DPFE voltage. There should be a noticable difference in RPM's with the EGR open
Clean out the EGR valve and/or tubing to remove deposits
Check the voltage at the DPFE, compare to specified values (refer to a repair manual for your specific model)
Replace the DPFE sensor (with a good quality / OEM one)
Replace the EGR valve
P1504 - Intake Air Control circuit malfunction
The problem likely is a defective IAC valve. You can check the valve by unplugging the IAC and checking the resistance between the 2 wiring pins, should be between 6 to 13 ohms. Also check the resistance from the pins to the IAC body, meter should read open circuit, any resistance reading from the pins to the IAC body indicates a short. I doubt that there is a problem in the wiring harness or PCM, it is possible and should not be ruled out, although it is not seen often.
P1537
Intake Manifold Runner Control Stuck Open
P1504
Intake Air Control circuit malfunction
P1506
Idle Air Control Over Speed Error
P0112 Intake Air Temperature Circuit Low Input
P0113 Intake Air Temperature Circuit High Input
P0133 02 Sensor Circuit Slow Response (Bank 1 Sensor 1)
P0420 Catalyst System Efficiency Below Threshold (Bank 1)
P0743 Torque Converter Clutch Circuit Electrical
I hate to hear you are havine so much trouble. These are a basic descrition of each of the codes.
If each of these codes are active, i would imagine you windstar isn
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