Easy EGR carbon clog fix

My Gen 1 (that I bought new in 1998) is a standard cab 4x4, 2.7L 3RZ FE with 326,000 miles.

I had a check engine light come on with "restricted flow" EGR code (P0401). The first EGR problem I've ever had.

After changing the Vacuum control switch, EGR valve and Vacuum modulator I gave up and took it to a mechanic who said the intake manifold was clogged with carbon and he'd need to remove the manifold to clean it, which would cost big bucks.

I declined took it home and fixed it myself. Here's what I did. I removed the EGR valve and sprayed carburetor cleaner into the manifold port behind the EGR valve. After a bit I took a skinny "bamboo skewer" (like used for shish kabob or satay) and used it to rooter out the port, and shot carburetor cleaner in until there was no more blow back.

Put it together, the code cleared and now it runs GREAT again and it cost pretty much nothing but a few hours.

 

which port did you clean out? i just looked at EGR and not sure what you meant. Im having same issue with same engine around the same mileage! want to try this before i spend money on parts!

Thanks!

 

Would this be something we should do like with cleaning the MAF or the carburetor?

 

The port I cleaned is the one in the intake manifold where the EGR connects. There is a large port just behind the EGR and then a narrow "tube" port that feeds the EGR gasses from the large port into the intake manifold. The narrow one was plugged up in my intake manifold. The caution is to keep the skewer long. If you decide to cut it, make absolutely sure that you don't cut the skewer too short. If it's too short you risk losing it inside the port. If that happened I'm not sure if you'd ever get it out (and may have to get a new intake manifold)!

 

Watterdog, NOTED! I may try to use a piece of #10 or 12 THHN SOLID as a probe to clean out the ports, little less chance of it breaking off . Thanks for the heads up and quick response!!

I'll respond with results after work today!

 

BTW.. (parts reminder) You'll have to completely disassemble the EGR system, so at the minimum, parts wise, you'll need all three gaskets (two for EGR Valve and one for EGR tube connection at exhaust manifold..

Also, I'm not sure how much checking you've done, but make sure the clog isn't in the EGR valve or the EGR valve crossover tube. Would be a bummer to pull the whole thing apart and find it was one of them after it was put back together. And remember to check the EGR valve with a vacuum pump to make sure it's working properly.

 

I wouldn't.

 

Good for you! You did your best. Congratulations, and thank you for sharing this with us!

 

Yep, I've used those for automotive stuff. They're also great for mixing and applying epoxy into tight spots. Let's save the turkey baster and liquid measuring cup for another thread.