there is a tear in the diaphragm causing moisture and carbon from the exhaust. order a new one.
P0401 "egr insufficient flow" can indicate many things, including: 1-vacuum line plugged or leaking 2-pipe from exhaust to egr valve plugged 3-pipe to vacuum modulator valve from egr valve plugged 4-passages at egr are plugged 5-bad egr valve 6-bad EGR VACUUM MODULATOR VALVE I tried cleaning egr modulator valve, (beside/above egr)removed and tested egr vacuum & movement, inspected and cleaned all vacuum lines openings and pipes. All above did not work. I replaced the egr vacuum modulator valve. Light went out without a reset in about 30 miles of driving. Not sure if this valve can be cleaned. Retails for $69.US
EGR stands for Exhaust Gas Recirculation. The purpose of the EGR system is to lower the amount of oxides of nitrogen the engine produces. The parts of the system are the vacuum actuated EGR control valve, the vacuum switching valve, and the EGR vacuum modulator assembly.
Buy a new part and mount it to the firewall by the egr valve and connect the wires and vacumm lines and leave old one on block.
The EGR system has two main parts: EGR Vacuum Modulator and EGR Valve. The EGR Vacuum Modulator is easy to find at the top-rear of the engine. It is round and has several vacuum hoses attached to it. This part can be removed by twisting/pulling the hoses and sliding it out of it's bracket. There is a filter inside the top cap of the EGR Vacuum Modulator which can be cleaned with soapy water. Dry it thoroughly after cleaning. The EGR Valve, also round, is directly below the Modulator and connected to the modulator via a vacuum hose. It can be removed by removing two 13mm nuts, one vacuum hose and one electrical connector. The electrical connector simply unplugs. NOTE: There is a thin gasket between the valve and the head. Do not lose this. Once you have the EGR Valve removed, detach the tube with the phillips-head screw and then Unscrew the EGR Gas Temp Sensor (the part with the wire). Clean the EGR Valve with engine cleaner or carb cleaner or parts cleaner. Mine was FULL of thick oil/gunk. Clean the gasket, the temp sensor and the mating parts. Clean any gunk out of the hole in the head (a flexible mirror will help you see what's in there). Re-assemble everything. Don't forget to put the filter back into the Modulator. NOTE: The Modulator filter goes in with the smooth side down toward the ground. Reset your Check Engine fuse (15 Amp - located inside the under-hood fuse box).
The Vacuum switching valve controls the EGR Valve.
On top of the engine to the right rear of the valve cover is a round plastic unit sort of hat shaped of black plastic with three vacuum hoses coming from it. This is your EGR vacuum modulator. Two hose come out toward the front of the car and one toward the rear and down. Follow this hose and it should go to your EGR valve.
Remove the EGR valve vacuum lines. Remove the EGR valve retaining screws. Wash the EGR valve in hot water. Allow the valve to thoroughly dry before installing it.
The EGR (Exhaust Gas Recirculation) valve opens when vacuum is applied. The EGR vacuum solenoid opens and closes the vacuum supply to the EGR valve when it is commanded to do so by the ECM (Engine Control Module).
If your EGR valve is vacuum operated, simply remove the vacuum hose from the valve.
It's almost impossible to tell just from how engine is working. Unless you have hesitation, car lacks power and efficiency is low. And of course if you have EGR error code(s). In order to test EGR you need to have a small vacuum hand pump. Then you need to apply vacuum to the EGR system and see how it responses. Also, sometime EGR valve just needs to be cleaned. For the you need to remove the valve and check on presence of carbon deposits. Also if the valve itself cannot be moved freely, it might have to be replaced. The hoses around EGR system have to be checked on cracks, and replaced if cracks are present. EGR vacuum switching valve usually does not break. But EGR valve get very dirty time to time and has to be cleaned or replaced.
There won't be any vacuum to the egr while idling. Engine must be warmed up and under acceleration or cruising before vacuum opens egr valve.
There won't be any vacuum to the egr while idling. Engine must be warmed up and under acceleration or cruising before vacuum opens egr valve.