I have a 1999 Contour SE Sport with the V6. It's automatic with a/c and VIN code L. I got my first CEL the other day, code 401, insufficient EGR flow. I found the green vacuum line to the EGR had broken, so I repaired that and used the scan tool to reset the codes. I drove it for about 3 days and the same code came up again. I hooked up the computer and reved up the engine to where the pcm was calling for the EGR to open. I was getting vacuum to the line that hooks on the EGR. This told me that the solenoid is working ok and I have no further vacuum leaks (I also checked the other hoses). I either have a bad sensor, a seized EGR/broken diaphragm, tubing from exhaust or egr itself is stopped up with carbon, or one of the sensing tubes that connects the sensing unit to the EGR exhuast tube is plugged. I hope all that made sense. Is there any particular problem that seems most dominant? I've been warned to be careful about taking off the EGR as in loosening the exhaust tube, it can break off and then you got a real mess. I was unable to get it loose anyways as it's impossible to get a wrench due to the air intake box and the brake reservoir/booster. Any ideas are appreciated.
