Tag: egr

Acura and Honda vehicles with V6 engines, having problems with EGR trouble codes PO401 or P1491 and/or engine pinging.

Acura and Honda’s with V6 engines, with EGR trouble codes and/or engine pinging. Check engine light on with DTC’s PO401 (insufficient EGR flow) or P1491 (insufficient EGR lift), This problem is due to the EGR port being clogged causing the failure. Honda has issued a TSB (Technical Service Bulletins) TSB-99-085 for the corrective action for cleaning the EGR port, and installing new EGR pipe kit. TechSmart™ has also released a similar solution for unclogging and replacing the EGR port tube.

The TechSmart™ EGR fix consist of a tool kit B22001 a coated, stepped drill bit and a punch tool. The repair kit F23001, includes a new EGR tube, throttle body and EGR valve gasket.

Corrective Action for Cleaning the EGR port, and installing the EGR Pipe Kit
Applies For:
1998-00 Accords V6 – ALL
2001 Accord V6 – 4-door from VIN 1 HGCG 1…1 A000001 thru  1 HGCG1…1 A058564
2001 Accord V6 – 2-door from VIN 1 HGCG2…1 AO00001 thru   t HGCG2…1A023388

BACKGROUND: In some areas of the U.S., certain basic chemical properties of gasoline (regardless of brand) may cause the intake manifold EGR port to clog or the EGR valve to fail. If this happens, the MIL comes on with a DTC P0401 (insufficient EGR flow) or P1491 (insufficient EGR lift) stored.

1. Remove the throttle body cover, intake manifold covers, ignition wire holder, and ignition wire cover.

2. Disconnect the brake booster vacuum hose and the vacuum hose from the intake manifold
3. Remove the throttle body from the intake manifold (two nuts and two bolts). Leave all hoses, cables, and electrical connectors connected to the throttle body. Discard the throttle body gasket.

4. Remove the PCV valve from the cylinder head cover. Remove the intake manifold (three nuts and six bolts).
5. Remove the intake manifold chamber, IAT sensor, boost plate, and PCV hose from the intake manifold.

6. Cover the six ports on the bottom of the manifold with duct tape.

7. Use a 8-mm drill bit and carburetor cleaner to clean the EGR port in the intake manifold. Turn the drill bit only by hand. Do not use a power drill.
8. Put the special drill bit from the EGR pipe installation kit in your power drill. Coat the drill bit completely with clean engine oil. NOTE: The oil coating is critical to drilling the hole accurately, and it contributes to drill bit life.
9. Insert the guide part of the drill bit into the EGR port. Make sure it is inserted fully. Then drill out the EGR port using steady pressure on the drill Make sure the port is drilled through completely.

10. Clean up the aluminum Chips from drilling, then remove the duct tape.
11. Put the Manifold in a parts washer (solvent or soap and water) and clean it thoroughly.
• Flush out the EGR port for 20 seconds.
• Flush out the manifold from the throttle body opening. Run cleaner down each side for 20 seconds.
• Flush each intake runner for 10 seconds. Start at the throttle body end and work towards the back.
• Turn the manifold so the throttle body opening is facing down. Flush each main runner for 20 seconds.
• Dry the manifold with compressed air and clean shop towels.

12. Place the EGR pipe from the kit into the EGR port.

13. Use the installation tool and a small hammer to drive the EGR pipe into the port until it is flush with the port. Make sure the pipe will not contact the gasket after installation.

14. Install the intake manifold chamber; torque the nuts and bolts to 12 N•m (8.7 lb-ft). Install the IAT sensor; torque it to 18 N•m (13 lb-ft). Install the boost plate; torque the bolts to 12 N•m (8.7 lb-ft). Install the PCV hose.
15. Inspect the EGR port in the front of the injector base on the engine. If it is partially or fully clogged, clean the port.
16. Disconnect the 6P connector from the EGR valve. Remove the
EGR valve.

17. Install the new EGR valve with newly supplied gasket; Torque the mounting nuts to 22 N•m (16 Ib-ft). Reconnect the 6P connector.
18. Install the intake manifold with the original gasket. Torque the mounting nuts and bolts to 22 N•m (18 lb-ft) sequentially in two or three steps. Route the PCV hose so it is not pinched under the intake manifold.

19. Install the PCV valve in the cylinder head cover.
20. Install the throttle body with a new gasket. Torque the mounting nuts and baits to 22 N•m (18 Ib-ft).
21. Reinstall the brake booster vacuum hose, vacuum hose, ignition wire holder, and all of the covers.
22. Connect the PGM Tester (loaded with SN200 or later software). Clear any DTCs.
23. Use the PGM Tester to override two-trip error detection.
• From the PGM tester menu, select 1. Honda Systems.
• Then select 2. SCS.
24. Test-drive the vehicle to make sure no new OTCs are set.


B22001 Tool kit
2001-2003,1997-1999 Acura CL
2003-2009 Acura MDX
1999-2008 Acura TL
1998-2007 Honda Accord
1999-2007 Honda Odyssey
2003-2008 Honda Pilot
2006-2008 Honda Ridgeline
2004-2007 Saturn Vue

F23001 Repair Kit
1999 Acura TL
1998-2001 Honda Accord
2006-2008 Honda Ridgeline
2004-2007 Saturn Vue

Ford F250 F350 F450 F550 Super Duty Power Stroke 6.0L Turbocharged Diesel lossing coolant or over-heating? What is a EGR Cooler?

The diesel engine uses a compression-ignition system, meaning that it uses the heat of compression to initiate a spark-ignition to burn the air-fuel mixture.  Using this style of internal combustion has it advantages and disadvantages.  The diesel engine has the highest thermal efficiency of any combustion engine using this method of heat along with high compression ratio for better efficiency.  This also is it’s weakness, due to the amount of heat the engine as to deal with.  That is why the diesel engine requires a EGR Cooler, needing to cool the recirculation of the exhaust gasses to maintain a acceptable operating temperature while  complying with federal emissions standards.

How does a EGR Cooler work?  The exhaust gasses are directed through the Exhaust Gas Recirculation (EGR) System Cooler to remove heat before the exhaust gasses arrive at the EGR valve.  This system uses engine coolant to reduce the exhaust gas temperature entering the intake.   Unfortunately this system deals with extremely high temperatures which fatigues the metal components causing cracks.  Which seems to be a common problem on most diesel engines.  For example on the Ford Power Stroke 6.0L Turbocharged Diesel you don’t even know there is a problem, just a slow coolant loss.  At first you may notice just a loss of coolant with no leak.  As this condition gets worse, you’ll see white clouds of smoke from the exhaust pipe.  This is the coolant leaking through the cooler into the intake and vaporizing, exiting out the exhaust pipe.

APDTY now offeres a solution for the EGR cooler problems with a redesigned EGR cooler that has a larger tubing design instead of the original small fin designed (similar to a radiator).  This new cooler is re-manufactured and improved by removing the factory fin design and replaced with bigger thicker stainless steel tubes that allow the exhaust gas to cool without the chance of cracking & mixing with coolant which is the main cause of failure on the factory original units.

2010-05 Ford 6.0L Diesel EGR Cooler Tubular Upgrade

With the 6.0L Power Stroke, another problem leading up to the EGR cooler failure is often the oil cooler.  Coolant first flows through the oil cooler before the EGR Cooler, this oil cooler is know for plugging up and restricting flow to the EGR cooler.  Without the coolant flowing the engine temperatures will become extremely hot, starting a pattern of overheating failures with the EGR cooler and engine oil temperatures.  This could eventually lead to failures of the oil pump, fuel injectors and turbocharger problems. A tale-tail sign of your oil cooler going bad is coolant boiling out of the overflow bottle.  We also carry and recommend the factory original Ford Oil Cooler repair kit, part # 3C3Z6A642CA to be replaced at the same time as the cooler.

FORD OEM Part Number 3C3Z6A642CA

Replacing the EGR Cooler requires that the turbocharger and intake manifold be removed.  To make this replacement easy,  Apdty offers several other parts related to repairing the Ford Super Duty 6.0L Turbo Diesel EGR Problem.

Ford OEM EGR Cooler/Intake Gasket Kit for the 6.0L  Turbo Diesel.

2004-2009 Intake Manifold 5C3Z-9424-A

Dorman Products offers a Turbo hardware kit including the o-rings, gasket and bolts needed for doing this job.  Dorman part number 904-234.



EGR Problem? What does the EGR System do? How to fix, repair the most common failures of the EGR System. Replacing the EGR Solenoid and Transducer on Chrysler, Dodge, Plymouth, Eagle, Jeep, GMC and Mitsubishi vehicles.

What does the EGR system do?  The function of the EGR system is to reduce oxides of nitrogen (NOX) in exhaust emissions, reduces cylinder combustion temperatures and helps prevent spark knock. The EGR system allows a predetermind amount of exhaust gas to recirculate and dilute the incoming air/fuel mixture to reduce peak temperatures during combustion.

When is the EGR system needed? The amount of emissions NOx produced at low engine speeds is very small, and is not needed at idle. It is also not needed during wide-open throttle driving, to achieve efficient acceleration. Recirculation is required during cruising and non-wide-open acceleration at speeds between 30 to 70 mph, when NOx formation is highest.

The EGR system consist of a EGR Valve, EGR solenoid, EGR backpressure transducer, signal tube and hoses. The solenoid operation is controlled by Powertrain Control Module (PCM) and the EGR backpressure transducer operation is controlled by the exhaust system backpressure.

Most faluires of the EGR systems are due to the transducer and solenoid. TechSmart™  manufactured by SMP, now offers a quicker and more cost effective solution for replacing just the fualty transducer and solenoid, perfectly matching the OEM EGR valve specifications.

EGR System- Solenoid,Valve and Transducer

G28001 — 2000 Chrysler Voyager / Grand Voyager | 2000-1996 Chrysler Town & Country | 2000-1996 Dodge Light Truck Caravan / Grand Caravan | 2000-1996 Plymouth Voyager / Grand Voyager

G28002 — 1993-1990 Chrysler Imperial | 1993-1990 Chrysler New Yorker | 1993-1990 Dodge Dynasty | 1993-1991 Chrysler Dynasty | 1994 Chrysler Intrepid | 1995-1990 Chrysler Town & Country | 1995-1990 Dodge Light Truck Caravan / Grand Caravan | 1995-1990 Plymouth Voyager / Grand Voyager | 1995,1993 Chrysler Intrepid | 1995-1993 Chrysler Concorde | 1995-1993 Dodge Intrepid | 1995-1993 Eagle Vision | 1999-1996 Dodge Neon | 1999-1996 Plymouth Neon

G28003 — 1993 Jeep Grand Wagoneer | 1996-1992 Dodge Light Truck Dakota | 1996-1992 Dodge Light Truck Pickup – Fullsize / Ramcharger | 1996-1992 Dodge Light Truck Van – Fullsize | 1996-1993 Jeep Grand Cherokee

G28004 — 2000-1995 Chrysler Cirrus | 2000-1995 Dodge Stratus | 2000-1996 Chrysler Sebring

G28005 — 2002-2001 Chrysler Town & Country | 2002-2001 Chrysler Voyager / Grand Voyager | 2002-2001 Dodge Light Truck Caravan / Grand Caravan

G28006 — 1996-1995 Chrysler New Yorker | 1997-1995 Chrysler Concorde | 1997-1995 Chrysler Intrepid | 1997-1995 Chrysler LHS | 1997-1995 Dodge Intrepid | 1997-1995 Eagle Vision

G28007 — 2000 Chrysler Voyager / Grand Voyager | 2000-1996 Dodge Light Truck Caravan / Grand Caravan | 2000-1996 Plymouth Voyager / Grand Voyager

G28008 — 2000,1997 Chrysler Cirrus | 2000-1997 Dodge Stratus | 2000-1997 Plymouth Breeze | 1998-1997 Chrysler Sebring

G28009 — 1986 GMC Light Truck G Series Fullsize Van / Savana | 1996-1992 Dodge Light Truck Dakota | 1996-1992 Dodge Light Truck Pickup – Fullsize / Ramcharger | 1996-1992 Dodge Light Truck Van – Fullsize

G28010 — 2002-2001 Chrysler PT Cruiser

G28011 — 1997-1995 Chrysler Sebring | 1997-1995 Dodge Avenger

G28012 — 1989 Dodge Lancer | 1990 Dodge Light Truck Caravan / Grand Caravan | 1990 Plymouth Voyager / Grand Voyager | 1991-1989 Chrysler Daytona | 1991-1989 Chrysler LeBaron | 1991-1989 Dodge Daytona | 1991-1989 Dodge Shadow | 1991-1989 Dodge Spirit | 1991-1989 Plymouth Acclaim | 1991-1989 Plymouth Sundance

G28013 — 1998-1995 Eagle Talon | 1999-1995 Chrysler Sebring | 1999-1995 Dodge Avenger | 1999-1995 Mitsubishi Eclipse

G28014 — 1989-1988 Dodge Light Truck Pickup – Fullsize / Ramcharger | 1989-1988 Dodge Light Truck Van – Fullsize

G28015 — 2000-1998 Chrysler Sebring | 2000-1998 Dodge Avenger

G28016 — 1997-1996 Dodge Stratus | 1997-1996 Plymouth Breeze

G28017 — 2000-1999 Plymouth Voyager / Grand Voyager | 2002-2000 Chrysler Voyager / Grand Voyager | 2002-1999 Dodge Light Truck Caravan / Grand Caravan

G28018— 1992 Chrysler Dynasty | 1993-1992 Chrysler Daytona | 1993-1992 Chrysler LeBaron | 1993-1992 Dodge Daytona | 1993-1992 Dodge Dynasty | 1994-1992 Dodge Shadow | 1994-1992 Plymouth Sundance | 1995-1992 Dodge Spirit | 1995-1992 Dodge Light Truck Caravan / Grand Caravan | 1995-1992 Plymouth Acclaim | 1995-1992 Plymouth Voyager / Grand Voyager

G28019 — 1995 Dodge Neon | 1995 Plymouth Neon

G28020 — 2000 Chrysler Cirrus | 2000-1997 Dodge Stratus | 2000-1997 Plymouth Breeze

G28021 — 1996 Chrysler Sebring | 1996-1995 Chrysler Cirrus | 1996-1995 Dodge Stratus

G28022 — 1995,1993 Chrysler Intrepid | 1995-1993 Chrysler Concorde | 1995-1993 Dodge Intrepid | 1995-1993 Eagle Vision

G28023 — 1996 Chrysler Concorde | 1997-1996 Chrysler Intrepid | 1997-1996 Dodge Intrepid | 1997-1996 Eagle Vision

G28024 — 1994 Chrysler LHS | 1994 Chrysler New Yorker | 1994-1993 Chrysler Concorde | 1994-1993 Chrysler Intrepid | 1994-1993 Dodge Intrepid | 1994-1993 Eagle Vision

G28025 — 1996-1994 Dodge Light Truck Pickup – Fullsize / Ramcharger

Ford Vechicles with repeated false EGR codes, due to Delta Pressure Feedback of EGR (DPFE) Hose having vacuum leak

Ford vehicles with Pressure Feedback EGR Sensors (PFE) or Differential Pressure Feedback EGR Sensor (DPFE), may experience repeated false codes for the EGR system. This condition may be due to a hose problem, this hose is subject to high temperatures (melting) and carbon debris blockage.

Other than a repeated check engine light, some driveability conditions that may be experienced include engine bucking (surging) during initial off-idle acceleration or cruising and may become as bad as engine stalling during deceleration.

This TechSmart™ kit is a real problem solver featuring an extra heavy-duty hi-temp design to handle the pressure that ordinary hoses cannot.

DPFE hose kit M40001

Delta Pressure Feedback of EGR (DPFE)  part # M40001

2000-1995 Lincoln Town Car
2000-1998 Ford Contour
2000-1998 Mercury Grand Marquis
2000-1998 Mercury Mystique�
2000-1999, 1995-1994 Mercury Cougar
2001-1996 Ford Light Truck Explorer / Sport / Sport Trac
2001-1997 Ford Light Truck Windstar
2001-1997 Mercury Mountaineer
2002 Ford Thunderbird
2002 Lincoln Blackwood�
2002-2000 Lincoln Ls
2002-1997 Ford Escort�
2002-1998, 1995 Ford Crown Victoria
2002-1999 Lincoln Continental
2004-2003 Ford Light Truck E Series Medium Duty Van
2004-2003 Mazda Tribute
2004-2003, 2000 Ford Focus�
2004-1996 Ford Light Truck E Series Fullsize Van
2004-1996 Ford Light Truck F Series Fullsize Pickup
2004-1997 Ford Light Truck Expedition
2004-98 Lincoln Navigator�
2004-1998, 1995-1994 Ford Mustang�
2005 Lincoln Aviator�
2005-2000 Ford Light Truck Excursion
2005-2003, 2000-1998 Mercury Sable
2007-2003, 2000-1996 Ford Taurus
2007-2005 Mercury Mariner
2007-1998 Ford Light Truck Ranger
2007-1998 Mazda Pickup�
2008-2003 Ford Light Truck Escape
1994 Mercury Capri�
1996 Ford Light Truck Bronco
1999-1998 Mercury Tracer

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