I'm working on it tomorrow morning, but as soon as I get any new info on it, I'll let you all know! I put an excerpt from the Windstar forum down below. It seems kinda relevant to the problem you (Louie), and I have. This is what I'm doing tomorrow. As for the O2 sensors, I have no idea since my electrical experience is nowhere near my mechanical experience. Ray, Jim, anything to add?
Windstar Forum
"Posted by wrestler
REMOVE | ALERT | EDIT 31-Jul-03 at 08:51 AM (ET)
@ 577
Please, folks...if you get a recurring P0171 code, or anything pertaining to EGR flow, and the engine is running okay, remove your EGR DPFE sensor, tap it in your hand with the ports DOWN and you will see moisture. This is condensation that gets trapped in the EGR tube. (BAD DESIGN!)
As you start your engine in the mornings (especially humid), you blast all that moisture into the sensor because the EGR valve is closed at idle. It shorts out, giving you a light, and that stupid code.
One remedy, although repetitious, is to spray the sensor innards with computer cleaner. Do that, reinstall it, clear the code (disconnect battery, then reconnect), and it won't come back for a while. This will keep you from wasting any more money on new sensors. There's nothing wrong with them...it's a bad system design problem.
I'm working on my own solution to this, (since Ford is either unwilling or unable to) which will be one or both of these steps...
1) Relocate the sensor with longer hoses, and extended wire
2) Add a small vacuum line directly from the "High" side hose tap to the intake manifold to provide a constant vacuum source which will continuously draw off the accumulated moisture before it makes it to the sensor.
I'll keep you posted on how this works out. In my case, it's the ONLY item that triggers that damned light."
All along I thought us Contour owners had it bad! Those Windstars seem to be plaqued by each of our problems, plus their own unique ones! It's another place to look since I've completely ruled out a vacuum leak (I've put pressure, and vacuum to everything possible). Good luck, and you can expect a reply from myself sometime tomorrow around noon. Goodnight!
Sean
