Contour Enthusiasts Group Archives Forums General Troubleshooting CE light...need some help

Ok, my 96 SE has had the CE light for about a month now. My shop pulled a code 401 and 408...now I know what 401 is (insufficient EGR flow) but I couldn't even find a listing for 408 anywhere?? Anyway, I've only replaced the DPFE sensor, the EGR valve itself looks fine and the car is running alright. Before I changed the DPFE the car would have an erratic idle when cold (bobbing up and down before settling to a normal idle) and according to my wife the car did stall a couple times. After the new DPFE the car runs better, but I still have the CE light with the damn 401 code, and whatever the hell 408 is. I've done some searching here through the forums (yes, I DID do a search b4 asking this question ) but most of what I found was related to EXCESSIVE EGR flow (402)...and I have the opposite condition. As far as I know the passages are clean, I didn't tear into it personally but my shop says everything looks good (and I deal with a competant, trustworthy shop).

On a side note, the car has a nasty a$$ sulfur smell whenever you step on the gas & get past 5k. It's been that way ever since I got the car, initially I had a bad 02 sensor, figured that was the cause so I replaced it but the smell remained.

Anyway, my shop is suspicious that the ECM is bad...I'd rather get some more opinions before I go messing with the brains. Anyone have some advice on this situation?

The 1996 Ford TSP does not list P0408, so I did a little research on the web...

According to http://www.obdii.com/codes.html, and a few other sites, P0408 means "Exhaust Gas Recirculation Sensor B Circuit High". Don't know what that means though.

Did you reset the CEL codes after you replaced the DPFE? I suggest that you reset the CEL, drive it for a while, and see if anything else shows up.

Since you have a 96, have you had the ENGINE HARNESS RECALL done ?

Engine harness recall? Nope, haven't had that done. Would that set an EGR code though???

The CE light has been reset SEVERAL times since the new DPFE...all with the same result, 401 & 408

What made you replace the DPFE?

Your bad sulfer smell is comming from too high of a sulfer content in the gas that you are using. Try another brand. I know around here most of the Contour guys only use Sunoco gas because it has the lowest sulfer content of all. I don't know if this available where you are, but do some research, it can't hurt.

A very lean mixture will cause a sulfur smell too.

My shop pulled an EGR code, found nothing wrong with the EGR and went to the next logical step. Apparently the DFE WAS bad since the car is running/idling better than before. I have an excellent aftermarket warranty, so I don't mind dropping the car off at my shop to let them work on it. However, they can't figure out this CE problem, and I absolutely REFUSE to go to any of the crap ass ford dealers around here, because none of them are honest and they hate working with aftermarket warranty companies. In fact when the CE light first came on I took the car to the dealer, they simply ran codes, said the EGR needed cleaning and it wasn't covered under warranty, $80 diagnostic charge

That's why I'm turning here...since none of the "experts" can seem to find the problem I guess I'll do it myself, with all of your help of course

Incidently, the sulfur smell has been coming from the car ever since I got it a year and a half ago. I've used all different types of fuel and octane, to no avail. And I always thought a RICH condition would give this smell, not lean.....am I mistaken?

I don't think that replacing the DPFE would make the car idle any better, since the EGR system does not kick in at idle.

There are no "easy" remedies to an EGR problem, since there are a lot of possible fixes. The following text comes from the Ford Technical Service Publication (TSP) on a P0401:

The easiest thing that you can do is visually inspect the vacuum hoses to make sure that there are no cracks or leaks.

After that, you will need tools to test each of the components. I have found Alex Peper's Vehicle Explorer software to be the best tool for this situation, since it will give readings on the DPFE and EVR (aka EGR VR). Another good tool is a hand-held vacuum gauge.

If you just want to replace parts one at a time, then the next one to replace would probably be the EVR (since you already replaced the DPFE and you say that the EGR valve is good). This part costs around $15-25 and is easy to replace (just remove two screws, the electrical connecter, and the two vacuum hoses). You could probably do it yourself.

One last thing, how did your shop check the EGR valve? Are you positive that it is OK?

I can't say for certain how the shop checked the egr...though they do have a good track record for finding problems so I feel pretty confident that, if they say the EGR is ok then it is, but anything is possible. I considered changing the EGR myself, it looks pretty damn simple but I hate spending money that isn't necessary. Perhaps that will be my next move. Thanks!