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Old 06-23-2010, 10:15 PM   #1
SBXLI93
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1999 SL2
2003 ION-3 Sedan
Default Blocked EGR intake manifold port

I'll make this short....Rebuilt engine in April of this year. Cleaned intake manifold as best I could, but I believe I have developed a blockage in the EGR intake port. I keep getting P0405 codes. Fuel mileage has gone from first tank of 35.88 to a 31.5 and sometimes a 29.3 to 25.5. The ETCS is new and no corrosion on plug wires. Had some corrosion on EGR plug wires and pins, cleaned them as well. Then I started to get a code of P0401: A ckt low voltage. Replaced EGR and within two days same code. Got my money back and replaced with new EGR from autozone #21008421 milege jumped up to 31.5 and then back down to 29. Got code#405 again. Is there a way to unblock the intake passageway from EGR to Intake manifold with out taking off car? And yes Old Nuc I tried your method of removing EGR valve and starting car to blow out build up. Car never went to rev limiter on it's on but did sound like I had no muffler on. And one more thig I did rewire egr plug since one of the connectors was rusted .
...
1999 SL2 748k miles
engine and tranny rebuilt
36.5 mpg
Now I am ready to go for another 500,000!
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Old 06-24-2010, 12:09 AM   #2
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1998 SC2
Default Re: Blocked EGR intake manifold port

If it did not rev up your plug/blockage is on the intake side. Go get a chunk of old speedometer cable and remove the EGR and roto-root out the passage into the intake.

If you replaced the connector, exactly how did you do this? Best method is to get a good connector and a chunk of wire from a junker and then solder it into your car. Do not use crimp connectors.

The 401 sounds like the plugged intake side and the 405 is probably a connection issue.

Last edited by OldNuc; 06-24-2010 at 12:16 AM.
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Old 09-22-2012, 01:05 AM   #3
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1999 SC2
Default Re: Blocked EGR intake manifold port

what is roto root?.... do u mean try to push the carbon inside the passage until it gets into the intake mani?
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Old 09-27-2012, 07:29 PM   #4
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Default Re: Blocked EGR intake manifold port

also where is the egr port within the intake manfold? i cant to find it even after seafoam did a great job at taking out the black carbon.

a picture or a diagrams out there?

thanks
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