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Help with 02 OZ Rally

Old 03-27-2014, 12:40 PM
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Join Date: Mar 2014
Location: WI, USA
Posts: 4
Default Help with 02 OZ Rally

I tried searching the forums before posting but did not see anything similar to my issue. I hope I am not double posting..

For the past few months my fiance's 02 OZ Rally keeps throwing a P0401 Exhaust Gas Re circulation Flow Insufficient Detected.
This code will only throw when driving in town (low speeds) or when drastic speed changes occur (say 70 down to 35)
I have tried:
Cleaning the EGR Valve
Checked for blockage \ Cleaned the hoses
Cleaned the vacuum Valve.

All of the above seem to do nothing.
I have even gone the route of replacing the EGR Valve.
Funny thing is, if the new EGR valve is installed, the car begins to sputter in idle and wants to die. Two codes will then throw:
Codes are P401 EGR and P0300 Random / Multiple Misfire.

If Gas is applied with the new EGR installed, car smooths out in the high RPMS, but once it returns to 800 to 1000 rpms its idles rough again.

IF i swap the new EGR back out and place the old EGR back in, car runs smooth in idle but still throws the code 401 when driving as indicated above.

Anybody have any ideas / input on this? Im sorta stumped. Tried searching google but could not find anything close to this for this car.

Old 03-27-2014, 12:53 PM
Senior Member
Join Date: Mar 2014
Posts: 200

What brand of EGR did you buy? Sounds like it is defective and sticking open. Th EGR only opens at full throttle. If it opens at idle, it will cause the engine to die.
Old 03-27-2014, 12:56 PM
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Join Date: Mar 2014
Location: WI, USA
Posts: 4

Its oem from the dealer.
Old 01-30-2015, 09:20 AM
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Join Date: Jan 2015
Posts: 7

So? Have you found your problem yet?
Mine is around 500 RPM and is choking. When the engine warms up, sit around 800 RPM and stabilize.
Old 01-31-2015, 07:16 PM
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Thread Starter
Join Date: Mar 2014
Location: WI, USA
Posts: 4

Unfortunately not. Iv reverted back to the old EGR valve and left the check engine light on. Still throwing the 401 code. Hoping this year I will get it into the dealer with the new EGR and let them have at it. Ill keep you posted.

Last edited by XxW1ZYxX; 01-31-2015 at 07:21 PM.
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