Montero sport egr insufficient flow

SOURCE: p0401 egr flow insufficient

The EGR valve is usually to the right side of motor triangular shape which has 3 screws.There is a metal pipe coming underneath which send excess "smoke" thro it. It tends to carbon up so needs to be cleaned.There are also 3 "pintle valves" on springs inside and the springs could be weakened/carboned up causing the valves to remain open/shut.

SOURCE: How do I remove the intake manifold on my 03

That is all the basic stuff unless you feel you need to change injectors or knock sensor which probably isn't necessary. The intake has about 8 bolts that you can remove after all vacuum lines are disconected. If you would like further detail and illustrations, I suggest go to autozone.com and register for free, then you can view a full free online repair manual

SOURCE: 2001 MONTERO SPORT 6CLY 3.0L

what a wiring nightmare...

SOURCE: 2001 MONTERO SPORT 3.0L 6CYL

Follow the vacuum lines on the egr valve to the solenoid that actuates the egr valve. Check the fig and see the yellow arrow pointing solenoid and the white arrow is pointing to the EGR.:--
Check out.Thanks.

SOURCE: 2001 montero sport looking for

Hi,

The P0403 code represents a problem with the Exhaust Gas Recirculation Solenoid or circuit.Below is the chart that explains and directs us to where the problem may exist.





Since there are a number of components or wires that can be at fault for this code,I feel it is not going to be something that we should attempt to diagnose via long distance. You may wish to check the basic wiring and vacuum supply to the solenoid, but if you find that the ECM is at fault, you will want to have this type of problem backed up by a good part and labor warranty.
Most solenoids need about 20 ohms or slightly higher resistance on the primary winding circuits to function correctly.

1. Using the VACUUM HOSE ROUTING as a guide, check to be sure that the vacuum hoses are correctly connected.
2. Check the connection condition of the vacuum hoses, (removed, loose, etc.) and check to be sure that there are no bends or damage.

Be sure to clear any trouble codes after you have made any repairs to the system.
Below is a technical service bulletin I have located on your vehicle, It may or may not be related to your current problem. I simply wanted you to have it.
TSB Revision: TSB-06-13-012
DATE: September, 2006
MODEL: See below

SUBJECT:
EGR SYSTEM TROUBLESHOOTING
- SERVICE MANUAL REVISION

PURPOSE
This bulletin contains additional troubleshooting procedures for the vacuum controlled EGR system on the affected vehicles.

Write the TSB revision number of this bulletin in the "TSB Revision" box at the bottom of the affected service manual pages.
AFFECTED VEHICLES
1995-1996 Mirage 1.5L and 1.8L (California emissions only)
1996 Mirage 1.5L and 1.8L (Federal emissions only)
1997-2002 Mirage 1.5L and 1.8L
2003-2006 Lancer 2.0L
2003-2006 Lancer Evolution
2003 Outlander
1996 Galant 2.4L
1997-1998 Galant 2.4L (Federal emissions only)
1999-2003 Galant 2.4L and 3.0L
1995-1999 Eclipse/Eclipse Spyder 420A and 2.0L Turbo
1996-1999 Eclipse/Eclipse Spyder 2.4L
2000-2005 Eclipse/Eclipse Spyder 2.4L and 3.0L
1996-1999 3000GT 3.0L
1996 Diamante 3.0L
1997-2004 Diamante 3.5L
1996 Montero 3.0L 12 valve
1996 Montero 3.0L 24 valve (Federal emissions only)
1996 Montero 3.5L
1997-2000 Montero 3.5L (Federal emissions only)
2001-2002 Montero 3.5L
1997-1999 Montero Sport 2.4L (Federal emissions only)
1997-1998 Montero Sport 3.0L (Federal emissions only)
1999-2003 Montero Sport 3.0L
1999-2004 Montero Sport 3.5L
1996 Truck 2.4L
1995 Expo/Expo LRV 1.8L and 2.4L (California emissions only)
1996 Expo/Expo LRV 1.8L and 2.4L (Federal emissions only)


Let me know,if needed further assistance.

Hope i helped you.

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