P0401 Code
Hotshot
Joined: Dec 2003
Posts: 15,368
Likes: 121
From: Stuttgart, Ar
Well my CEL came back on this afternoon so it looks like I'll just go ahead and put in a new EGR valve. but before i do this I would like to clean underneath it one more time and also clean under the intake and drive for a few days so i dont mess up the new one. To take off the intake elbow is all that is required to take off the black hose and the 4 bolts? is there a gasket under there that i need to replace? Thanks again for the help.
Lead Driver
Joined: Mar 2010
Posts: 5,504
Likes: 256
From: Woodbridge, Ontario, CA
Well my CEL came back on this afternoon so it looks like I'll just go ahead and put in a new EGR valve. but before i do this I would like to clean underneath it one more time and also clean under the intake and drive for a few days so i dont mess up the new one. To take off the intake elbow is all that is required to take off the black hose and the 4 bolts? is there a gasket under there that i need to replace? Thanks again for the help.
Fleet Owner
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
Remove the four 8mm bolts that secure the air intake to the intake manifold. LOOSEN the 11mm CAC hose clamp loose enough that you can simply spin the air intake on the black plastic hose upside down. DO NOT separate it from the hose or remove it or you will have one hell of a time trying to re-install the hose back onto the air intake. And no there is no gasket that needs to be replaced.
IF you ever have to remove it I would pull the elbow and not remove the
plastic CAC pipe. It's less of a PITA at the intercooler end but still takes
time and I found a bit of heat from a hair dryer or a heat gun set on low.
One thing you can do is use the shop vac to suck up as much as you can
from the openings after you brush the carbon off.
A long handled pipe brush would work. I would stick to brass and not a steel
one. If you can't find that look for a pipe brush
Here is a link to a brush supplier. I bet you can find something suitable at a
your local industrial supply or Grainger Industrial Supply
They are a very good place to find some of the odd ball tools like the brushed
Sean
Thread Starter
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Senior User
Joined: Aug 2011
Posts: 240
Likes: 0
From: Central arkansas
Thanks for the help, I took the black pipe off when I did the blue spring upgrade and couldn't get it back on until i warmed it up with a heat gun then it just popped back on. Thanks for the idea of the brush, I work at an industrial supply house so i'll pick up a brush monday at work and then get them cleaned out.
Do you think i would be ok pulling the intake elbow and EGR valve and cleaning below both and then put back in the same old ( only 3 days) o-ring and gasket for a few days to keep from messing up the new EGR valve i will get this week?
Do you think i would be ok pulling the intake elbow and EGR valve and cleaning below both and then put back in the same old ( only 3 days) o-ring and gasket for a few days to keep from messing up the new EGR valve i will get this week?
Thread Starter
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Senior User
Joined: Aug 2011
Posts: 240
Likes: 0
From: Central arkansas
Well i've cleaned my EGR valve twice and took the intake elbo off and cleaned but it didn't appear to be very bad compaired to other pictures ive seen. I've burned about 5 tanks of fuel since this started and have run Diesel Kleen gray bottles in all. everytime I turn the CEL with the SGII it comes back on within 20min.
I also noticed that my hot side CAC boots have some oil on them. also i noticed that the most boost i can build is about 24psi and at WOT it drops to about 20psi. before i just start throwing parts at this i wanted to see what your thoughts are? have a good evening.
I also noticed that my hot side CAC boots have some oil on them. also i noticed that the most boost i can build is about 24psi and at WOT it drops to about 20psi. before i just start throwing parts at this i wanted to see what your thoughts are? have a good evening.
Lead Driver
Joined: Mar 2010
Posts: 5,504
Likes: 256
From: Woodbridge, Ontario, CA
I will assume it's P0401 returning unless you tell me differently. Have you actually installed a NEW EGR valve? How about the intake? How badly were the passages clogged with carbon? If you've cleaned out IAT #2 as well, that only leaves a badly clogged up EGR cooler intake passages. If it is in fact the EGR passages in the EGR cooler itself that are badly clogged up causing P0401 to return, the only way to resolve that issue is to either pull the EGR cooler to clean out the passages with tune-up or carb cleaner, or replace the cooler itself outright. Either way, if you choose to pursue this, you might as well have your intake manifold sent out and hot-tanked since it will need to be removed anyways to access the EGR cooler.
Elder User
Joined: Jul 2012
Posts: 834
Likes: 0
From: tonopah, az
Im thinking turbo or up pipe. And you can't hot tank an aluminum intake. Simple green soak and car wash imo.
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Fleet Owner
Joined: Apr 2012
Posts: 27,307
Likes: 549
From: Spanaway
Sorry for the 
M-Chan
If a person is running with the EGR turned off will that also plug up the cooler?
Or will it just deadhead at the scoop and not get much soot into the cooler?
Thanks
Sean
M-Chan
If a person is running with the EGR turned off will that also plug up the cooler?
Or will it just deadhead at the scoop and not get much soot into the cooler?
Thanks
Sean
Thread Starter
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Senior User
Joined: Aug 2011
Posts: 240
Likes: 0
From: Central arkansas
It was the p0401 came back. I just ordered a new egr valve from tousled ford so it should be here Friday hopefully. I'll get it put in and see if that fixes it. Thanks for all of the help so far, I will post back up when done with how it works
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Senior User
Joined: Aug 2011
Posts: 240
Likes: 0
From: Central arkansas
Well the UPS truck dropped off my new EGR valve today and got it switched out and went for a 30 min drive. Light didn't come back on yet so its so far so good.
However i did notice the most boost i can get is still 23psi while my foot on the floor and then it is dropping to 20psi before it shifts. any thoughts?
Also thanks to everyone for all of the help on my EGR valve.
However i did notice the most boost i can get is still 23psi while my foot on the floor and then it is dropping to 20psi before it shifts. any thoughts?
Also thanks to everyone for all of the help on my EGR valve.
Lead Driver
Joined: Mar 2010
Posts: 5,504
Likes: 256
From: Woodbridge, Ontario, CA
At this point, it needs to be connected to IDS and have what's called an "Air Management Test" ran on it, to determine which parameter is out of spec.
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Senior User
Joined: Aug 2011
Posts: 240
Likes: 0
From: Central arkansas
is this something a dealership would have to do or should most shops be able to do this?