This is on a 2001 Focus but I'm sure the question can be answered.

I keep getting a code 0401 for insufficient EGR flow. You can fell a wierd hesitation or pulsing when driving.

I have removed the egr valve and cleaned it up even though everything looked clean and seemed to be functioning.

I checked all the lines and wires and everything seems ok. Still getting the code.

I was thinking two things.......either the diaphrame in the egr valve has an issue and isn't opening when needed. Or the electrical component (dont' know what this is called? EGR Vacuum Regulator?)....is not commanding the proper, if any vacuum to the EGR itself.

I wanted to see if I could take care of it myself before getting the dealer involved. Just cost me 900 bucks to have the alternator, battery, cables and rear window fixed!!!

 

Most likely the DPFE sensor is bad. Common problem. Ford has extended the coverage on the part to two years and 24,000 additional miles from warranty start date on the Focus. If you have less than 60,000 miles, you can get it fixed for free at a dealer. If not, I suggest going to the dealer and buy the updated part and install it yourself. The hoses are two different sizes, so be careful where you install them.

Robbie

 

Great Info. What does DPFE stand for so when I call they will know what i'm talking about.

 

Delta Pressure Feedback Egr sensor. Trust me, they will know what you are talking about, we replace them all the time.

Robbie

 

I'll probably get a little flack for sugesting this, but the way I've checked the diaphragm in an EGR before is by pulling off the vacuum line to the EGR valve (engine off) and sucking with my mouth (doesn't taste good) and then holding the suction in like you would by holding your finger on the end of a straw with soda in it. After a few seconds release the vacuum. You can hear the EGR popping up and down if it's good. If the diaphragm was broken it wouldn't hold the suction because it would pass through the diaphragm. Just a word of caution, it rarely is due to the EGR valve itself. Bigbronc's suggestion above makes much more sense as the most likely cause.

 

i went i picked one up. I told the parts guy I needed a sensor for a ford focus and he walked away and came back. I was like I didn't even tell you what one. He was like..........you don't have to........haha.

It does look different then anything on the car i've seen. Maybe they changed them?? Anyone know exactly where it's located on a 01 focus?