Am getting the engine light about once a week (I reset it - it will stay off a while then come back on). It always reports P0401 Low EGR flow. This is the Japam made camry for those that know the differences.
I replaced the EGR valve and gaskets - verified the ports were not clogged (used pipe cleaners and ran them through until they were sticking inside the manifold). I replaced the diaphram filter thing next to the EGR with the hoses interconnecting between them - all hoses are clear and I used only real Toyota parts.
I checked the VSV valve and I think it's acting abnormally. After warming up the engine - I can quickly increase rpms to 3000 and I notice the EGR valve opens for just a split second and then closes - even if I hold the RPMS. It does this repeatedly. I found that the VSV valve is causing it - opening the air flow just for a second, then blocking it again. So - there's no situation when the EGR valve stays open - even at 3000 rpms. Maybe this is normal for this car, but maybe it's not - any ideas? I bought the vsv valve too when I got the other parts but I hadn't put it in yet because it was so hard to get to. Any suggestions on how to get to that valve are welcome too. I did the vacuum drop test recommended by an earlier post (connected a vacuum guage to the manifold - was reading pretty high - around 24, then I manually opened the EGR valve with the engine holding at 3000 rpms, The vacuum did drop 3 on the gauge.)
One note: I got a MIL error saying the front O2 sensor heater had failed before I had the problem with the EGR error. I replaced that O2 sensor (also with geniune Toyota part) and it wasn't a week later I got the first EGR P0401 error. Could be bad luck - but if I got a flakey 02 sensor - how would I know? Does anyone know how to test one using a multimeter and what readings I should look for?
Please advise on the EGR VSV valve suspect problem (is it working normally but turning off right after turning on?
Please advise on best way to get at the VSV valve to change it. (can't seem to reach it front the top or bottom.
Please advise on how to test the O2 sensor when I have only a multimeter. I have an electronics background - I just don't have a Toyota tester.
Thank you all very much for any advise - this has been a frustrating problem. I will do what it takes to fix it but I don't want to keep buying parts that don't solve the problem. The car is a 4 cylinder automatic and has 70k miles on it.