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Old 10-24-2005, 02:00 PM   #1
Kevin94SL
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Default EGR Issues

'99SL1 128,000km.

Car is throwing a p0401 (Insufficent EGR flow). EGR valve has been replaced twice. Question I now have... Could this be a problem with vacuum lines on this??? Could there be a crack in one of the lines? I have been told that a different code will be thrown if there was an electrical problem with the valve.

Car is running okay, but obviously this is something that I would like to get fixed.

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Old 10-24-2005, 05:37 PM   #2
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Default Re: EGR Issues

Clean the EGR valve instead of replacing it and save some money

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Old 10-24-2005, 05:45 PM   #3
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Default Re: EGR Issues

When you replaced the EGR, did you clean out the ports on the manifold? They can get awfully carboned up & REALLY restrict flow. I've used a flathead screwdriver in the past to clear some of that shtuff off (don't necessarily recommend that approach) but a good amount of carb spray & a stiff brush couldn't hurt.

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Old 10-24-2005, 09:46 PM   #4
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Default Re: EGR Issues

Quote:
Originally Posted by Kevin94SL
'99SL1 128,000km.

Car is throwing a p0401 (Insufficent EGR flow). EGR valve has been replaced twice. Question I now have... Could this be a problem with vacuum lines on this??? Could there be a crack in one of the lines? I have been told that a different code will be thrown if there was an electrical problem with the valve.

Car is running okay, but obviously this is something that I would like to get fixed.
As mentioned already clean out the EGR passages with a something like GM combustion chamber cleaner. Dissolves carbon very well.

Side note.

The 99 model year uses an electronicly operated EGR valve. No vacuum lines for it at all.

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Old 10-25-2005, 10:08 AM   #5
Kevin94SL
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Default Re: EGR Issues

The reason that the EGR valve is being REPLACED and not just cleaned, is that it is a warranty issue. I've only been driving the car for about 3 weeks.

I don't know what they did when replacing as I haven't been standing beside them. I would assume that things would be cleaned, but can't guarantee it. I will give that suggestion when I take the car back in.

SSICarman.... Thanks for the tip about being all electrical. Was looking in a... Haynes (I think) manual for '91-'99 just to see what the deal was and it was mentioning electical as well as vacuum connections - I didn't actually go out and look under the hood at it.

I think that my father will be running the car down this time, so I will mention to him about the cleanliness of everything and see what can be done.

Thanks all for your help.

...
Kevin

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Old 10-26-2005, 09:31 AM   #6
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Default One small speck of carbon....

Cleaned, new, whatever, all you need (((>and you've got the kms <))) is one small speck of carbon to clog the EGR open. That has happened to me, within two days of a full cleaning job. One small carbon speck >>>

BTW, I've not purchased a new EGR in the last 6 years..... I simply remove, replace with my backup, and then clean out the 'removed' unit.

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Old 10-26-2005, 01:42 PM   #7
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Default Re: EGR Issues

Been searching forums and was wondering if this is cure for my car problems.
My 1994 S saturn just recently started bucking upon acceleration. Used dry gas and fuel injection cleaner. Have put new plugs wires and fuel filter in and checked the fuel pressure all seems fine. But it continues to buck. It idles fine. I'm to the point of going to a dealer for a diagnostic check but hate to spend the money. Could the egr be the problem?

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Old 10-26-2005, 01:59 PM   #8
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Default Re: EGR Issues

Absolutely could. And it is an easy job.

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Old 10-26-2005, 02:24 PM   #9
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Default Re: EGR Issues

Thanks, I have the manual but it really doesn't go into the egr so will try to clean.

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Old 10-26-2005, 09:02 PM   #10
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Default Re: EGR Issues

Quote:
Originally Posted by cherylt
Been searching forums and was wondering if this is cure for my car problems.
My 1994 S saturn just recently started bucking upon acceleration. Used dry gas and fuel injection cleaner. Have put new plugs wires and fuel filter in and checked the fuel pressure all seems fine. But it continues to buck. It idles fine. I'm to the point of going to a dealer for a diagnostic check but hate to spend the money. Could the egr be the problem?

If you have the vacuum operated EGR you may have a different problem. Is the bucking under light throttle application, as in slow parking lot kind of driving? If it is then the vacuum bleed on the EGR may be plugged.

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Old 10-27-2005, 07:56 AM   #11
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Default Re: EGR Issues

It bucks mainly at acceleration while trying to get up to speed. Once up to speed it is not too bad. It is getting worse and is real bad if going up hill. I am not sure if I have a vacuum egr will have to check. Will try to clean EGR tonight after work, weather permitting.

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Old 10-27-2005, 09:46 AM   #12
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Default Re: EGR Issues

A PS to my last post....You mentioned the vacuum bleed being plugged? This stuff is new to me so here's the dumb question. Where would the vacuum bleed be? I know there is a small hose off the egr or would it be elsewhere. I'm relying on the little electrical diagram under the hood for locating most of this stuff.

Tks cheryl

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Old 10-27-2005, 10:18 AM   #13
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Default Re: EGR Issues

Most '94s have a vacumn operated EGR valve. The linear EGR valve doesn't have any vacumn hoses going to it.

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Old 10-27-2005, 10:35 AM   #14
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Default Re: EGR Issues

Quote:
Originally Posted by cherylt
It bucks mainly at acceleration while trying to get up to speed. Once up to speed it is not too bad. It is getting worse and is real bad if going up hill. I am not sure if I have a vacuum egr will have to check. Will try to clean EGR tonight after work, weather permitting.
Just unplug the vacuum line from the egr valve and see if the problem disappears.

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Old 10-27-2005, 11:13 AM   #15
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Thumbs Up Re: EGR Issues

If I unplug the vacuum line prior to driving is what your saying, Ill give that a shot before I drive home this afternoon.

I really appreciate all the feedback.

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Old 10-28-2005, 07:39 PM   #16
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Default Re: EGR Issues

Quote:
Originally Posted by cherylt
If I unplug the vacuum line prior to driving is what your saying, Ill give that a shot before I drive home this afternoon.

I really appreciate all the feedback.
UPDATE: Cleaned EGR(looked like the original) so replaced it

Still bucking upon acceleration, rechecked spark plugs,wires and cleaned pcv valve(new 2 months ago) and replaced hose from pcv valve(it was cracked).

I also tried it with the vacuum hose unhooked from egr.

I'm open for any and all suggestions.

So the shopping list so far is:
New EGR
New fuel filter
Checked fuel pressure
new air filter,
New pcv valve and hose
dry gas
injector cleaner

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Old 10-28-2005, 11:22 PM   #17
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Default Re: EGR Issues

Vac bleed is built into the EGR valve it self. If it is plugged then the valve will need to be replaced.

How are you cehcking the plug wires? With an ohm meter? Checked the coils? Especially for corrosion on the plug wire towers?

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Old 10-29-2005, 12:06 AM   #18
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Default Re: EGR Issues

Did not check plug wire with meter, just visual check. I was just reading through all the forums and saw mention of the coil packs. So tomorrow I'll check. Any advice on what I'm actually looking for is appreciated. It's just me and my haynes manual and of course this forum.

Someone at work mentioned a bad catalytic converter could cause this, is that another option and is there a way to check.

thanks

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Old 10-29-2005, 01:06 AM   #19
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Default Re: EGR Issues

You don't wnat anymore than 10,000 ohms max per plug wire. That is even high. The shorterthe wire the lower then resistance. If you have infinate resistance or open readings then the wire is no good. Approx 8,000 ohms across the coil towers and infinate from a tower to ground.

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Old 10-29-2005, 12:53 PM   #20
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Default Re: EGR Issues

Quote:
Originally Posted by ssicarman
You don't wnat anymore than 10,000 ohms max per plug wire. That is even high. The shorterthe wire the lower then resistance. If you have infinate resistance or open readings then the wire is no good. Approx 8,000 ohms across the coil towers and infinate from a tower to ground.
Well, I think problem fixed. This AM called a local garage to check price of having car diagnosed. I told him the problem and said change spark plug wires. I told him I had just changed them recently and he said that the wires with the long boots are notorious for being bad. He said he had seem them be bad in under a month. So bought new wires and plugs (didn't go cheap this time) and changed them.
Took a short test drive and seems fine, now I'm taking my daughter to the mall (ugh) and this will be the real test, lots of hills and highway driving.

Don't regret putting in new egr and fuel filter etc, the mileage was terrible and both looked like original parts.

Will do final post after trip.

Once again thanks for all the help, I bought wires with a lifetime warranty and thinking about just swapping them out every six months or so.

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