EGR code P0401 insufficient flow?

Tiny
TROUBLEDXYZ
  • MEMBER
  • 2005 CHEVROLET MALIBU
  • 3.5L
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 266,000 MILES
Car doesn’t have symptoms that I’ve read come with an EGR issue. Runs pretty well and I think mileage is ok for the age of the car 25mpg ish. I was told to replace the valve so I went through hassle trying to find the part. Tried pick n pull replacement, cleaned it and the original, and installed a brand new one. None of that fixed the check engine light. Cleaning and visual inspection of valve and manifold area indicate low carbon deposits and easy movement of valve.

I’ve read lots since and none of the described diagnostic testing has been done and from what I’ve read, I’m coming to the conclusion that the EGR valve itself is not usually the cause of the EGR codes.

So, if your mechanic doesn’t know or do the tests, how do you actually find the cause or identify/find a mechanic that will actually diagnose instead of replacing this part replace that part.

If it is damaging the engine every time you drive it would be nice to find a way to fix it.
Monday, October 7th, 2024 AT 2:15 AM

3 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,643 POSTS
This does not damage the engine, this is easy to find out what is going on, remove the egr valve and start the engine, you should have exhaust coming out of one port and suction from the engine intake manifold on the other. If not, this will be the problem, and the ports will need to be cleaned, which is a super common problem with this many miles. You may need to keep the engines idle up by putting your foot on the gas pedal slightly. Check out the images (below). Please let us know what happens.
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Monday, October 7th, 2024 AT 10:40 AM
Tiny
TROUBLEDXYZ
  • MEMBER
  • 2 POSTS
Mechanic had the valve off and inspected it and inside hose and all ports and didn’t see any blockage. I’ll get him to try running engine with valve off but reading about this valve, it is clear as mud. Sounds like problems not caused by build up are common. How do you test to see if other parts in the emissions process are causing it?
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Wednesday, October 9th, 2024 AT 11:38 AM
Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,643 POSTS
It is a flow code, so it is just the EGR valve and the ports. Clean the ports and get a new valve which should fix it, clear the codes once completed.
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Thursday, October 10th, 2024 AT 11:30 AM

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