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Old 08-18-2019, 06:50 PM   #1
GMfromspace
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2001 SL2
Question Away from home!!, new EGR valve and a new problem

I'm really hoping someone can help me before I have to drive 3 hours thru redwoods with no cell service

Last week I replaced the EGR valve (including the gasket) on my 2001 SL2, and while the old one was off, I cleaned as much of the build up on the mount and in the immediate passage then started it and let it run for several minutes before installing the new one...... And yay! the SES light was no more. (Previous codes were P0404, P0405, P0446 - returned the next day, and P1404). I had already tried cleaning the valve, and with the desired position and low voltage detected codes, it was suggested I replace the solenoid. Unfortunately, the solenoid by itself cannot be shipped to California, hence replacing the entire valve. My Saturn has ran good since, no more stumbling on acceleration and fuel efficiency increased a bit. Until today......

I noticed this morning that there was a slight hesitation when I would accelerate to get on the freeway again, and just an hour ago, as I was exiting the freeway, coming to a stop at a light, suddenly it acted as though it was going to die, which has NEVER happened in the 4 years I have owned my Saturn, and I was able to get over while slipping into neutral (automatic tranny), and gunning it to about 3000 RPM's, then letting off, still wouldn't idle, repeated 3 or 4 times and finally found a steady idle at normal RPM's. Once I got to where I was going, I pulled out my OBD II and checked the codes. What it showed was P0401 (EGR flow insufficient detected, a [U]new[U] code, P0404 (EGR Control Circuit Range/Performance), and P0446 still ( I will be testing the purge cannister soon). I then drove about 2.5 miles to a park without issue.

Any suggestions of what I could or should do I would be so appreciative of! I am 3 hours away from home in a town where I do not know a soul, will be driving home through redwoods that block cell signals, but I do have basic tools (ratchets, sockets, wrenches, screwdrivers) and my multimeter, light tester, and OBD II code reader with me.


Thank you in advance!!

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Old 08-19-2019, 08:00 PM   #2
edlee
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1999 SL1
Default Re: Away from home!!, new EGR valve and a new problem

Someone else on these forums once wrote that he kept quarters for paying tolls and also for blocking the EGR ports in case the EGR valve started to malfunction. I've never tried that myself. Other people have mentioned spraying oven cleaner into the holes. I don't know if that works.

Last edited by edlee; 08-19-2019 at 08:01 PM.. Reason: minor edit

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Old 08-19-2019, 08:21 PM   #3
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Default Re: Away from home!!, new EGR valve and a new problem

Do not squirt ovan cleaner onto aluminum!!!

Block the valve by placing a coin over both ports on topof the gasket, replace valve and do not over tighten or it will break.

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Old 08-19-2019, 09:30 PM   #4
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Default Re: Away from home!!, new EGR valve and a new problem

"Unfortunately, the solenoid by itself cannot be shipped to California,"

That sounds odd to me. There is no separate "solenoid" on those EGR valves, I don't think you get one anywhere; at least not from a normal parts vendor.

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Old 08-20-2019, 11:21 AM   #5
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2001 SL2
Default Re: Away from home!!, new EGR valve and a new problem

Quote:
Originally Posted by OldNuc View Post
Do not squirt ovan cleaner onto aluminum!!!

Block the valve by placing a coin over both ports on topof the gasket, replace valve and do not over tighten or it will break.
Thank you OldNuc! The problem has yet to reoccur and the SES light has not yet come on again. I opted to stay put rather than attempt the drive home without cell service and will head back home later today after I do a couple of deliveries that require going on the freeway (I've had Google maps see to avoid freeways). But if it does happen again I will def try the coin method. And I would never, ever use oven current on anything in my engine..... My BBQ yes, my beloved Saturn Oven cleaner
Now to figure out which wire is loose behind the fuse box and how to replace it for the HVAC fan

Thank you again!

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Old 08-24-2019, 03:24 PM   #6
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Default Re: Away from home!!, new EGR valve and a new problem

the aftermarket EGR valves are not as good as the factory ones. Mine has done what you described at least three times in 4 years. Just put the car in 3rd gear and fine a decent road that you can safely drive the car in 3rd gear ( not D ) for 1-2 minutes at 4000 RPM. This will force the carbon out of the EGR Valve and you should be good for another 8 months or so.

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Old 08-24-2019, 11:08 PM   #7
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1998 SC2
Default Re: Away from home!!, new EGR valve and a new problem

Buy this part:EGR Klean Screen gasket Dorman part# 47007 and install it. This part number is for 2 EGR gaskets, 1 for FORD and another for GM. It really does fit a Saturn. This gasket will breakup carbon particles so the valve does not get stuck open and cause the engine to stall. It is a common parts store part.

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Old 08-25-2019, 03:29 AM   #8
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Default Re: Away from home!!, new EGR valve and a new problem

I think the ideaabout replacing the solenoid was probably made by someone who owned a Gen1 Saturn pre 1995.

1994 and earlier used a vacuum operated EGR that had an accuating solenoid.

Later models are electrically operated. No solenoid.

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Old 08-25-2019, 08:13 AM   #9
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Default Re: Away from home!!, new EGR valve and a new problem

Quote:
Originally Posted by onlinebiker View Post
I think the ideaabout replacing the solenoid was probably made by someone who owned a Gen1 Saturn pre 1995.

1994 and earlier used a vacuum operated EGR that had an accuating solenoid.

Later models are electrically operated. No solenoid.
Hmm, but solenoids ARE electrical. I don't know how a vacuum operated EGR would use a solenoid. They have vacuum diaphragms.

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Old 08-25-2019, 08:40 AM   #10
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1998 SC2
Default Re: Away from home!!, new EGR valve and a new problem

The vacuum is turned on and off with a solenoid.

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Old 08-25-2019, 01:24 PM   #11
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2002 SL1
Default Re: Away from home!!, new EGR valve and a new problem

I was going to say a carbon chunk and get a clean screen.

Pull the metal tube off the exhaust manifold and clean the Orr in the exhaust manifold for the blower and remove the egr valve and try and ru a wire in the port towards the exhaust manifold.

There is an insufficient flow code for the egr valve and the smog fan.

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