Found this forum while searching for fixes for my late sons 01 Edge. When we got it home there were no hoses between the EGR tube nipples and the DPFE sensor so I tried several things to hook it up and the hoses always burned up. Finally bent up some stainless tubing to fit with a stainless sleeve to fit the ends at the EGR end and rubber line at the sensor end. It seemed to work for short trips around town but took it on the loop around town this AM and seemed to have no power over 50 MPH and by the time I got back home I was smelling that burning rubber smell again from the rubber hose melting. Well I found the DPFE sensor melted at the hose fittings and also the electrical connector partially melted as well as some of the wiring below the intake when the stainless tubing fell on it. Something tells me that somewhere something is not working right. I could get another sensor and some of the high temp hose but don't want to burn up another expensive sensor from the exhaust gases. I'm about ready to block everything off and just live with the CEL and codes. Any help out there? Sorry for such a long first post.

Charles

 

Maybe you have a engine cooling problem. That may be why your hoses are melting. I dunno. Its just a guess but check your engine temp while driving around town. High temp hoses shouldn't melt unless the temp in the engine compartment goes over what the hoses are temp rated for.

 

Engine temps are normal. As stated in the first post, I bent up stainless tubes with short rubber hoses to connect everything. I didn't realize until later that they were supposed to high temp rubber. I had another suggestion that the exhaust may be restricted to cause this much pressure. I hope the pictures work.
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This pic is of the plastic that was melted and blown on th the underhood pad
Charles

 

What is the second picture of?

 

Read the line right between the pic & my sig.
Charles

 

It does look like exhaust fumes melted that because its melting from the bottom to the top. You might have an exhaust leak. Check the exhaust gaskets.

 

Except there are no exhaust gaskets in this location--All the exhaust came through the tube shown in the first picture. I am starting to wonder if the orifice on the other end of the tube has rusted off allowing the exhaust to flow through the tube.
Charles

 

Why would it rust in such a short period of time? I wonder if something strange is going on...

 

Did you have an oil consumption problem with your engine missing these parts?