[Turboman92]

After 30K miles of ownership, the P0401 code CEL showed up. There's definitely some EGR flow issue going on. It was reset last week and came back again a few days later. I since reset the fault and now it's coming back in 20 minutes of running the gas engine.

1. Is this covered under emissions warranty? (non CA resident)
2. I'm using top tier fuel i.e. Shell at every fill up, why am I still getting EGR foul up?
This car only has been running pure EV for 30K miles and gasoline for only 40K miles
3. Is the cold weather causing the car to run richer than normal and causing this?
4. How can I tell if it's a clogging issue versus an actual EGR valve failure?

I have a scheduled appointment with the dealer next week. I can only guess how much this is going to cost me.

Jeez, with the way there have been posts coming up recently on EGR issues and back ordered parts. Wouldn't be surprised if someone developed an EGR delete kit. Only challenge will be getting the ECU to ignore the following circuits:

• DTC P0401Exhaust Gas Recirculation (EGR) Flow Insufficient
• DTC P0403, P0489, or P0490 Exhaust Gas Recirculation (EGR) Control
• DTC P0404 or P042E Exhaust Gas Recirculation Open/Closed Position Performance
• DTC P0405 or P0406 Exhaust Gas Recirculation (EGR) Position Sensor
• DTC P040B, P040E or P041B-P041E Exhaust Gas Recirculation (EGR) Temperature Sensor

 

[Turboman92]

Just for giggles. Here is what the manual says for this:

DTC P0401
Exhaust Gas Recirculation (EGR) Flow Insufficient

Circuit/System Description
The ECM uses the exhaust gas recirculation (EGR) position sensor to determine the position of the EGR valve.
The engine control module (ECM) sends a pulse width modulated voltage signal to the EGR input signal circuit.
The ECM provides a voltage return path for the sensor through the low reference circuit. A pulse width
modulated signal, based on the EGR valve position, is sent from the sensor to the ECM through the EGR output
signal circuit. The ECM compares the actual EGR position with the desired EGR position when the EGR valve
is commanded open or closed.
Conditions for Running the DTC

• DTC P0068, P0101, P0102, P0103, P010B, P010C, P010D, P0111, P0112, P0113, P0114, P0117, P0118,
  • P0121, P0178, P0179, P0201, P0202, P0203, P0204, P0205, P0206, P0207, P0208, P0261, P0262,
  • P0264, P0265, P0267, P0268, P0270, P0271, P0273, P0274, P0276, P0277, P0279, P0280, P0282,
  • P0283, P0300, P0301, P0302, P0303, P0304, P0335, P0336, P0403, P0404, P0405, P0406, P042E,
  • P0489, P0490, P0502, P0503, P0506, P0507, P0604, P0641, P0651, P0722, P0723, P1104, P1248, P1249,
  • P124A, P124B, P124C, P124D, P124E, P124F, P1258, P1426, P1437, P2100, P2101, P2102, P2103,
  • P2147, P2148, P2150, P2151, P2153, P2154, P2156, P2157, P216B, P216C, P216E, P216F, P217B,
  • P217C, P217E, P217F, or P2269 is not set.
• Battery voltage is greater than 11 V.
• Barometric pressure (BARO) is greater than 70 kPa (10 PSI).
• Decel fuel cut-off state does not change for 250 ms.
• Mass air pressure (MAP) change is less than 1 kPa (0.15 PSI).
• MAP is between 20 - 50 kPa (3 - 7 PSI).
• The DTCs run continuously when the above conditions are met for 7 s.

Conditions for Setting the DTC
P0401

• The ECM detects the EGR flow is below a calibrated amount when the EGR is commanded ON.

Diagnostic Aids

• A stuck EGR valve or a restriction anywhere in the exhaust gas recirculation system due to excessive coking or
• debris may cause this DTC to set.