Honda - Accord :: 1998 - EGR Insufficient Flow Detected


Aug 26, 2014

I have a 98 Honda Accord, automatic, with a 3.0 VTEC engine with 189,350 miles. It was diagnosed with cod P0401: EGR insufficient flow detected.I was told and apparently in the instructions it states the following to repair/fix the problem:

Unplug the EGR Port in the Intake, remove upper portion of Intake Manifold, drill EGR port, install Sleeve and replace EGR Valve. Instructions also indicated I need a EGR Pipe kit: 06175 P8L-A00 which contains a special tool to drill manifold and install Sleeve: Kit 07ZAO-P8AA000.

Is this a easy job? I'm also confused about needing the special tool (I believe it's a drill bit) and drilling the port. Are either one of these two Kits I mentioned really needed? What do you recommend I use to clean the port? I thought I could just clean the port (hole) and replace the manifold gasket.

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My '96 4L developed the infamous P0401 insufficient EGR gas flow code 6 months ago. Rough running. Forgot to license it, now the St. Emissions Test was due before I could get new tabs issued. Finally got some warm dry weather to work on it. Started with the electrical measurements per DPFE graph of EGR flow vs electrical output to the PCM.

Showed the DPFE sensor failed, low V output max 2v. The old OEM aluminum body DPFE sensor was still in the old girl after 16 years. Corroded internally and ext., one hose nipple almost corroded off. Eureka. Put in a new Motorcraft plastic body upgrade. Same darn code.

Retested everything from the EGR vacuum valve that feeds the EGR valve to the new DPFE and then the EGR tube from the exhaust pipe. All tested ok electrically and leak wise. No fresh air leaks in the EGR V or EGR tube.

All pointed to restriction in EGR gas flow when PCM demanded it. Ran small stainless steel wire down the upper EGR tube line nipple to the EGR orifice trying to clear carbon build up, still the same P0401. Poured several cups of paint store acetone down each EGR tube hose with engine off and at 2k rpm to emulsify and dissolve the exhaust carbon out. Engine vacuum sucked the acetone up thru the EGR valve also cleaning it internally.

Let set overnight and took out for test drive. Still P0401. Almost ready to drive the green beast to the crusher of death.

Poured more acetone in the EGR and let set for 2 days prepared for the emissions station test failure then repair at emissions cert. shop with a shop waiver for no effective repair. Decided that the EGR tube or EGR valve were leaking fresh air, rusted and corroded. The end nuts on the tube were rusted away. EGR tube NLA from any source.

Went to the emissions test today and passed flying colors. NO P0401, drove all day on business. Got relicensed.

The old girl runs and drives like a dream, she's actually parked and sleeping in the garage tonight all pretty and shiny with a wash and wax job, got a reprieve from the Jaws of Death

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