P0401 insufficient flow. Hooked up vacc pump to egr valve. Engine did NOT react when valve was opened during idle as it should. Failing this test eliminates everything else in the egr system and points directly to the port from the egr valve to the intake runners. This port curver 90 degrees twice in the first few inches. It goes down vertical and turns 90 degrees to horizontal and then curves 90 degrees again toward the front of the engine. Not exactly the easiest thing to get the gift of tar and soot the EPA decided to bestow upon us out of once it clogs shut. This crap is very nasty. I sprayed carb cleaner in the port once I had the egr removed. If I sprayed enough of the stuff it would back up and run over the port like a clogged toilet confirming that it's clogged shut. Tried using a coat hanger bent in the shape of the port curve, but that didn't go in far enough before it hit an obstruction to do much good. Any ideas or suggestions short of removing the intake would be greatly appreciated. If I do have to remove the intake does it come apart in two pieces? It would be nice if only the top half has to come off. The nice thing about cleaning these things is as soon as you finish the job it starts clogging itself shut all over again. Thanks a lot EPA!

 

I just read the procedure for checking the EGR port for clogging by soot and tar from the exhaust. "Check the negative pressure port(EGR vacuum port) for signs of clogging. If clogged replace the part". I don't even care to know how much they want for the intake manifold at the local dealership. I can buy a whole log carb cleaner for that amount.

 

I feel for you...
I finally broke down and replaced the power steering high pressure hose that has been leaking for a couple of years now...it's a $200 part online and $270 from the dealer.
Good Luck