Engine code says egr valve insufficient flow. Replaced the EGR valve, cleaned the tube from exhaust to valve. Cleared the code. Ran for a day and engine code came back. Any suggestions?

 

check to make sure that the EGR valve is receiving manifold vacuum

the newer model rangers utilize a computer controlled vacuum port

the vacuum port may be plugged up with carbon or debris

 

Did this fix your issues? I am getting the same thing. I'll check the vacuum lines again..

 

DPFE sensor is the usual cause of the "insufficient flow" code, especially if you don't have pinging sound under load.
The Ford DPFE sensor lasts about 60k miles, replace with non-Ford model they seem to last longer.

Usual cause doesn't mean only cause, cleaning EGR valve and tube is free, also checking DPFE hoses and vacuum lines is free, so first do the free stuff, if code comes back replace DPFE sensor.

 

Replaced the egr block near the exhaust manifold. Didnt fix the check engine light

 

Not sure what the "EGR block" is???

EGR system has 3 parts
1. EGR Valve, vacuum hose is used to open valve and allow exhaust gases to enter intake when engine is under load

2. EGR modulator, computer controlled valve, it has electrical connector and 2 vacuum hoses, 1 to EGR valve and 1 to intake manifold, computer uses this valve to increase vacuum at EGR valve to open it.

3. DPFE sensor, it has electrical connector and 2 hoses to exhaust manifold, 1 hose is near, or on, the EGR valve tube, the other hose is on the exhaust manifold, this sensor detects pressure changes, if EGR valve opens the pressure in the hose near the EGR Valve will drop more than the pressure in the hose farther away, this pressure "differential" tells the computer how much exhaust gas is entering the intake thru the open EGR Valve, the "flow".
DPFE = differential pressure feedback
The two hose are marked and must not be reversed.

 

you should test the EGR valve with a manually operated hand vacuum pump to see if the valve inside is actually opening

there may excessive carbon that is blocking the valve from opening ( or in some cases " closing " )

 

Lots of good info.. I'll see how this helps this weekend when I have more time. Good stuff!!