2007 avensis D4D code po400

[mayfly]

The above suddenly put on elm trc and vsc lights today, we scanned it and shows fault code po400 which relates to egr. Took out egr which was completely sooted up and was actually stuck partly open. Cleaned it up and tried to clear code but no luck, code won't even clear with engine off. Does the egr motor give problems in these or is there anything else that can cause this problem. Cheers

[valhalla]

The main thing is to clean the manifold where the EGR valve is located, as there are a couple of "windows" in the casting that block-up. If you are getting a flowrate issue, then the chances are that the manifold itself is blocked. These are best cleaned with a "scoop", to prevent the carbon falling inside the manifold, to cause more problems later.

I have found the EGR valves on these to be one of the eaiest to clean, and definitely a major improvement on the usual Ford/GM fare. The valve needs to be dismantled on the bench, which takes a bit of working-out, IIRC, but is not difficult once the bulk of the carbon is removed. You definitely need to unpack the carbon from under the top of the pintle nearest the motor, otherwise you'll keep getting the same EGR codes. The pintle removes from the main EGR body. Unfortunately, I have no photos, just be assured that once you have cleaned the pintle, all will become obvious!

[Karl]

Last time I took an egr apart to clean it I couldn't get it back together again

And finally once I had , it wouldn't respond


.......... Yep needs a new one mate

[mayfly]

Thanks for replys. I took the egr appart,easy to remove from the engine and the actuation motor is just bolted to the egr with 3 bolts. Took it all apart and cleaned it completely. Also cleaned down in manifold , I didnt remove the manifold. What bothers me is that the code won't erase even with engine not running ,makes me wonder if it's an electrical issue. Will try and get a good second hand one to try, it's only 10 to 15 minutes to change.

[valhalla]

Yes, these are a decent bit of design, unlike the rest of the D4D engine, or its calibration.... I have promised the local guy with one of these that I'll clean the EGR valve at service time, it's so easy. Definitely important to get all the carbon out of the void behind the pintle, as that will throw a code when the valve first moves and ranges itself, engine running or not. It's a silly bit of design, having a "false valve head" on the top of the pintle to protect the bottom of the motor from the gas temperature, as one way or another, the carbon will blow round, then get packed every time the valve opens.

[Deleted]

Aug 27, 2015 21:16:34 GMT 1 mayfly said:

The above suddenly put on elm trc and vsc lights today, we scanned it and shows fault code po400 which relates to egr. Took out egr which was completely sooted up and was actually stuck partly open. Cleaned it up and tried to clear code but no luck, code won't even clear with engine off. Does the egr motor give problems in these or is there anything else that can cause this problem. Cheers

P0400 is generic and can have multiple meanings for egr problems , there is a difference between a code not clearing and a returning code !

[mayfly]

Thanks Valhalla for that, took it off again and soaked it for a couple of hours and cleaned it completely with carb cleaner,put it back and all was well again. Cheers

[valhalla]

Brilliant, glad that fixed it!

Like I said, this is a job that's so easy to do, it ought to be part of the service for the D4D, not least that they seem to run a fair old whack of EGR most of the time.

[Deleted]

These repairs should only be carried out by toyota official technicians as engine damage and stability safety issues are likely,.