How to change a EGR valve - 1999 Saturn SL

P0406 Chrysler - Exhaust Gas Recirculation Position Sensor Circuit High
Possible Causes:
- Faulty EGR volume control solenoid valve
- Carbon built up on EGR valve
- EGR volume control solenoid valve harness is open or shorted
- EGR volume control solenoid valve circuit poor electrical connection
- Faulty EGR temperature sensor and circuit

Did you replace the EGR valve, or the volume control solenoid valve?

If you need further help, reach me via phone at https://www.6ya.com/expert/daniel_4061c3d97c12c4c7

P0404 Dodge - Exhaust Gas Recirculation Position Sensor Performance Early Exhaust Gas Recirculation (EGR) systems component s include and EGR Valve, and Engine Control ?odule (EC?) Controlled Vacuum Switch Valve or EGR Solenoid and an EGR Vacuum ?odulator. Depending on the engine and driving conditions, the EC? will control the EGR Solenoid which will operate the EGR Vacuum ?odulator to regulate the opening and closing of the EGR Valve.
The EGR system on recently built vehicles uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the EC?. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the EC? does not issue the pulse signal. ? certain voltage signal is issued so that the valve remains at that particular opening.

code p0403 refers to EGR --circuit malfunction===causes ---wiring--EGR solenoid---ECM
code p0405 refers to EGR valve position sensor A --low input===causes ---wiring ---short to ground---EGRF valve position sensor--- ECM.
By only changing the EGR valve you have not fixed the problems that cause the valve not to work.

P0406 - Exhaust Gas Recirculation Sensor A Circuit High
An improper voltage signal is sent to ECM through the valve

Early Models : The EGR valve control the amount of exhaust gas routed to the intake manifold. Vacuum is applied to the EGR valve in response to the throttle opening. The vacuum control the movement of the taper valve connected to the vacuum diaphragm in the EGR valve.



Late Models : The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening.



Symptoms
- Engine Light ON (or Service Engine Soon Warning Light)
- Engine hesitation

Possible causes
- Harness or connectors (EGR volume control valve circuit is open or shorted.)
- EGR volume control solenoid valve
- EGR temperature sensor and circuit

Possible solution
- Repair EGR harness or connector
- Replaced EGR volume control solenoid valve
- Replaced EGR volume control valve


Hope helps (remember to rate and comment this answer).

The code P0401 is often not a problem with the EGR valve itself. Rather, the EGR system is not allowing enough EGR to flow back into the combustion process to sufficiently cool the peak firing temperatures. Once the code P401 has been retrieved with a scan tool, the freeze frame data should be documented and analyzed in order to determine what engine conditions were present when the code was triggered. It is recommended that the vehicle be driven in such a way as to duplicate the code setting conditions with a data streaming scan tool connected, so the behavior of the EGR actuating components and feedback sensors can be monitored.
Common Tests to Determine Whether the Problem Is an EGR Control Problem, a Plugged or Restricted System, or a Defective Feedback Device

• Does the engine die, not just stumble, when the EGR valve is manually raised to its maximum?
  (Use either a vacuum pump or bi-directional scan tool if it's a digital EGR valve.)
• Is the EGR valve getting sufficient vacuum? (Use the manufacturer EGR vacuum spec.)
• Is the EGR system restricted? (The engine stumbles, but does not die.)
• Is the EGR system plugged? (Engine RPM does not change.)
• Does the EGR valve work?
• Raise the RPM to 3000 and check manifold vacuum. Then open the EGR valve to its maximum-the manifold vacuum should drop by at least 3" of mercury. If it does not, there is a flow and/or restriction problem.
• Test the EGR temperature sensor (if equipped) with a propane torch and a DVOM.
• Test the accuracy of the EGR valve position sensor with a scan tool or DVOM by raising or lowering the EGR valve.
• Test the Digital EGR Pressure Feedback Sensor (DPFE) with a data streaming scan tool to verify that the voltage or lift percentage changes according to spec.
• Verify that the front Oxygen Sensor readings drop and the Short Term Fuel Trim increases when the EGR valve opens. (EGR leans out the mixture.)

P0406 - Exhaust Gas Recirculation Sensor A Circuit High

Early Models : The EGR valve control the amount of exhaust gas routed to the intake manifold. Vacuum is applied to the EGR valve in response to the throttle opening. The vacuum control the movement of the taper valve connected to the vacuum diaphragm in the EGR valve.



Late Models : The EGR volume control valve uses a step motor to control the flow rate of EGR from exhaust manifold. This motor has four winding phases. It operates according to the output pulse signal of the ECM. Two windings are turned ON and OFF in sequence. Each time an ON pulse is issued, the valve opens or closes, changing the flow rate. When no change in the flow rate is needed, the ECM does not issue the pulse signal. A certain voltage signal is issued so that the valve remains at that particular opening.



Symptoms
- Engine Light ON (or Service Engine Soon Warning Light)
- Engine hesitation

Possible causes
- Harness or connectors (EGR volume control valve circuit is open or shorted.)
- EGR volume control solenoid valve
- EGR temperature sensor and circuit

Possible solution
- Repair EGR harness or connector
- Replaced EGR volume control solenoid valve
- Replaced EGR volume control valve
When is the code detected?
- An improper voltage signal is sent to ECM through the valve


Hope helps.

OK, if you replaced the EGR hose, did you go all the way to change the EGR Valve? A stuck open EGR Valve can cause a rough idle and almost make it cut off.
Also, a vacuum leak on the EGR valve can cause a rough idle.

Exhaust Gas Recirculation (EGR) Valve Removal & Installation 2.0L Zetec Engine NOTE: When the EGR tube is disconnected from the EGR valve, it must be discarded and a new EGR tube must be installed. The aluminum threads on the EGR valve must be inspected, and a new EGR valve installed if the threads are damaged.
To Remove:

1. Disconnect the negative battery cable.
2. Remove and discard the exhaust manifold-to-EGR tube. Use the following as a guide:
3. Raise and safely support the vehicle
4. Remove the splash shield
5. Disconnect the EGR tube fitting
6. Lower the vehicle
7. Remove the air cleaner outlet pipe
8. Disconnect the EGR tube from the EGR valve.
9. Detach the vacuum line and remove the two retainer bolts.

NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:

1. Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.
2. Install a new EGR valve tube.

Detach the vacuum line (#1) and unbolt the EGR valve - 2.0L

3.0L (4v) Engine To Remove:

1. Disconnect the vacuum line.
2. Disconnect the EGR tube.
3. Remove the EGR valve and discard the gasket.

NOTE: The EGR valve sealing surfaces are soft metals and easily damaged.
To Install:

1. Installation is a reverse of the removal process. Carefully clean all sealing surfaces and install a new EGR valve gasket.

Detach the vacuum line (#1), unthread the EGR tube (#2) and remove the EGR valve bolts (#3) - 3.0L (4V)

probley not egr valve it probley egr control solenoid or wiring

I am fixing to change my EGR valve and the piece of paper that came with the part say this:

Important Notice
Before installing this part, check the EGR valve passage in the intake manifold and clear any carbon blockage. Failure to do so will result in repeat malfuntion of the EGR valve system. Refer to a technical service manual or contact a service dealer for proper cleaning procedures.

Hope this helps.

i would still try to change your egr!!! sometimes egr test good but still they can stick open and that can cause idle problems so if you want to get your prob fix change egr valve
take that egr off and put in a new one !!!!

Have a great day

Denis