Failed yearly smog safety inspection codes P0401 & P1537

1997 FORD E-SERIES VAN
10,000 MILES • 6 CYL • 2WD • AUTOMATIC
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MKWINKEL
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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?
Oct 27, 2008 at 8:35 PM
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RACEFAN966
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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.
Oct 28, 2008 at 9:33 AM
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MKWINKEL
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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?
Oct 29, 2008 at 6:31 AM
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RACEFAN966
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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.
Oct 29, 2008 at 9:52 AM
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MKWINKEL
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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.
Oct 31, 2008 at 5:49 PM
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MERLIN2021
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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


https://www.2carpros.com/forum/automotive_pictures/62217_imrc_1.jpg

This is the only picture I could find for you....
Oct 31, 2008 at 6:43 PM