95 V6 - Thowing code "Excessive EGR Flow", Clogged Cat? - Toyota Nation Forum : Toyota Car and Truck Forums


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Old 04-29-2009, 12:38 PM   #1 (permalink)
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3rd Generation 95 V6 - Thowing code "Excessive EGR Flow", Clogged Cat?

Hey all -

My 95 V6 has been throwing an "excessive EGR flow" code for a while (since mid-winter) and I've done the basic EGR/tube cleaning stuff, but it still hasn't fixed it.

Now that it's spring and I finally have the chance to floor it once in a while, it's like the power has just evaporated compared to last summer. Not wanting to just judge by my ass-dyno, I did a couple 0-60 runs on the highway. It takes me over 14 seconds to get to 60 now (alone in the car). That used to be around 7-8 secs IRRC. My 84 4-banger could get there quicker.

So, I'm wondering if I should rip the shit out of my EGR system, but it struck me that the cat has (probably) not been replaced for a long time and that could cause some excessive back-pressure and loss of power. Before I drop $400 on a replacement - does this make sense to anybody else?

-Thanks a million
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Old 04-29-2009, 01:38 PM   #2 (permalink)
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3rd Generation

If the cat is clogged it will usually be a lot more harmful than just throwing an EGR code. I also know the egr system will not generally negatively effect your performance if it isn't functional.

Check all the signs for now, plugs, tb, dist, wires, cap, rotor, and all your fluids.

If none of that works come back and let us know.
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Old 04-29-2009, 01:43 PM   #3 (permalink)
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Quote:
Originally Posted by JCamry94 View Post
If the cat is clogged it will usually be a lot more harmful than just throwing an EGR code. I also know the egr system will not generally negatively effect your performance if it isn't functional.

Check all the signs for now, plugs, tb, dist, wires, cap, rotor, and all your fluids.

If none of that works come back and let us know.
I checked all the standard "tune-up" items back in January. Everything looked fine, but it still kept throwing the code. Plugs and wires were first done about 20,000 ago, after the first 140,000.

One I didn't do - are the specific throttlebody check that I should be doing?
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Old 04-29-2009, 01:49 PM   #4 (permalink)
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Get a tooth brush and a bottle of deep creep seafoam and clean out the TB heavily.

A clogged up/dirty IAC can cause lots of problems.

How to: Cleaning Throttle Body -4 Cylinder Engines- With Pictures
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Old 04-29-2009, 02:17 PM   #5 (permalink)
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Quote:
Originally Posted by JCamry94 View Post
Get a tooth brush and a bottle of deep creep seafoam and clean out the TB heavily.

A clogged up/dirty IAC can cause lots of problems.

How to: Cleaning Throttle Body -4 Cylinder Engines- With Pictures
Will do. Thanks - I'll let you know how it turns out.
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Old 04-29-2009, 02:18 PM   #6 (permalink)
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hmm i haven't thought about it being my cat, but i'm actually running that code too... i'm now running that and egr flow insufficient, means i need a new one. but yea... i never had power loss... but do a good egr cleaning and you may feel power bck... hope it works and keep us posted!
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Old 04-29-2009, 03:01 PM   #7 (permalink)
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im experiancing this same code with my 97, but the car idles really rough. id check the EGR valve itself to see of it moves smoothly and check the EGR VSV. they seem to go slowly so ya may end up like my situation if they go bad. my problem seems to be the VSV that needs replacing.
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Old 04-29-2009, 03:12 PM   #8 (permalink)
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Originally Posted by bigbird View Post
im experiancing this same code with my 97, but the car idles really rough. id check the EGR valve itself to see of it moves smoothly and check the EGR VSV. they seem to go slowly so ya may end up like my situation if they go bad. my problem seems to be the VSV that needs replacing.
question, how do i check if the pin moves smoothly? lol
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Old 04-29-2009, 03:51 PM   #9 (permalink)
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Blocked kitty wouldn't be real high up on my list of possible causes of a P0402.

Apologies if you've already got an FSM in front of you, but the two reasons for throwing a P0402 (excessive EGR flow) are (1) EGR gas temp. sensor value is high during EGR cut–off when engine is cold and (2) EGR valve is always open.

The EGR system is relatively gnarly, so there's quite a bit of possible things to troubleshoot. Rather than parrot the FSM, I refer you to http://www.camrystuff.com/manuals/Gen3/eg2.pdf page 527 for a loose list of causes, and page 516 for the recommended troubleshooting flow.

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Old 04-29-2009, 04:29 PM   #10 (permalink)
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Originally Posted by hill8570 View Post
Blocked kitty wouldn't be real high up on my list of possible causes of a P0402.

Apologies if you've already got an FSM in front of you, but the two reasons for throwing a P0402 (excessive EGR flow) are (1) EGR gas temp. sensor value is high during EGR cut–off when engine is cold and (2) EGR valve is always open.

The EGR system is relatively gnarly, so there's quite a bit of possible things to troubleshoot. Rather than parrot the FSM, I refer you to http://www.camrystuff.com/manuals/Gen3/eg2.pdf page 527 for a loose list of causes, and page 516 for the recommended troubleshooting flow.
That's all well and good for the 402 error it keeps throwing at me (as I said, I haven't completely ripped the EGR system apart yet, since it seemed to run fine even with the code up), but could it also explain the gross loss in power? I'll try it either way, but everything I've seen seems to point to the EGR system not really robbing that much power when it's malfunctioning.

A 2x increase in 0-60 time points to a pretty huge power loss IMO. Like 50-80 HP. I'm going to clean up the TB and the EGR system, but is there anything else I should be looking for staring me in the face while I'm under the hood?
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Old 04-30-2009, 04:21 AM   #11 (permalink)
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you pull the egr off and just push on the valve to see if it is binding. but if the car isnt running rough then that would tell me its a sensor/electrical problem and not mechanical(mine is mechanical). try cleaning the sensor in the egr valve housing.
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Old 04-30-2009, 09:21 AM   #12 (permalink)
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sweet! ha ha, looks like i have something to do when i get home!
i had a feeling it would be the sensor because it does run smooth.
thnx ha ha
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Old 04-30-2009, 01:33 PM   #13 (permalink)
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Quote:
Originally Posted by Fruitbat View Post
That's all well and good for the 402 error it keeps throwing at me (as I said, I haven't completely ripped the EGR system apart yet, since it seemed to run fine even with the code up), but could it also explain the gross loss in power? I'll try it either way, but everything I've seen seems to point to the EGR system not really robbing that much power when it's malfunctioning.

A 2x increase in 0-60 time points to a pretty huge power loss IMO. Like 50-80 HP. I'm going to clean up the TB and the EGR system, but is there anything else I should be looking for staring me in the face while I'm under the hood?
Sorry, got so carried away with diagnosing the code I kind of ignored the bigger issue. You're right -- even if the EGR was stuck open or open more than needed, it wouldn't cause that huge power loss.

Are you getting more codes than the P0402? The power loss sort of sounds like the motor is in some sort of failsafe ("limp home") mode (such as extremely retarded timing), which would really make the engine fall on it's face. Offhand, 'tho, I can't think of a reasonable situation that would cause the ECU to fall back to a failsafe mode without throwing a code. I suppose an insanely sensitive knock sensor could cause that behavior, but usually knock sensors fail "dead", not noisy, and a dead knock sensor definitely throws a code.

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