Failed yearly smog safety inspection codes P0401 & P1537

MKWINKEL

MEMBER
1997 FORD E-SERIES VAN
6 CYL
2WD
AUTOMATIC
10,000 MILES

I had a brand new engine (0 miles) installed 10 months ago, it has been driven less than 10,000 miles. The codes that came up on the failed inspection are P0401 (EGR valve) & P1537 ( no description given). I took it back to the company that installed it and they thought they might have 2 certain vacuum lines reversed.

So they switched them and at about 40 MPH the engine started shaking and the service engine light flashing for about a minute. The code came up saying that #3 cylinder was misfiring. They changed the plug and wiring and they still got the same code. They switched the vacuum lines back and it stopped. But now we have the same code again about the EGR valve and some stuck flap in the engine. Both have been checked out and they are fine. Any ideas?

5 Replies

RACEFAN966

MECHANIC
5,029 POSTS

This code is intake manifold runner control stuck open, otherwise know as Idle Air Control Valve. If this is stuck open it will make the van run leaner then normal so you will get a lean code and egr(Maybe) and fail smog. So get it check and see if needs replacement or if the computer needs to be reflashed. Let me know how this goes.

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Tuesday, October 28th, 2008 AT 9:33 AM

MKWINKEL

MEMBER
3 POSTS

Thanks for your reply. I'll ask them about that. I did speak with them today to get a little bit more info. And they said the code coming up is for the MRH Flap. Is that what you are talking about? When they put the vacumn line the way they are suppose to be, #3 cyclinder misfires. When they switch them around they get a code about the MRH Flap. Do you know what could be happening?

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Wednesday, October 29th, 2008 AT 6:31 AM

RACEFAN966

MECHANIC
5,029 POSTS

I do not know what they are refering to as an MRH flap as there it nothing in books about that hoever the code you were questioning about is for the Idle Air Control Valve. I will look some more and if I come up with more I will let know. Get back to me on what they come up with for you.

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Wednesday, October 29th, 2008 AT 9:52 AM

MKWINKEL

MEMBER
3 POSTS

I showed the guys your reply and they said they have checked that out. They said the problem is that when they hook up the vacumn lines the way they are suppose to be #3 cyclinder misfires. When they put them the wrong way it doesn't pass inspection. It' gets the EGR valve code failure. They don't understand why the vacumn line correctly done is causing #3 cyclinder to misfire.

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Friday, October 31st, 2008 AT 5:49 PM

MERLIN2021

MECHANIC
17,250 POSTS

P0401 is EGR insufficient flow, do this: Yep! Pull the egr off, clean the port under it all the way to the throttle plate, I use a length of steel coat hanger...put it all back together, reset the codes, if light comes on again, replace the EGR position sensor, that's the one the two small hoses from the exhaust plug into! P1537= Intake manifold runner control, not the IAC

Here is a diagram for component location is case you needed it.

10/31/2008