Engine CAI code P0402 EGR Flow Excessive. What should I do?

CAI code P0402 EGR Flow Excessive. What should I do?

Hey-

Well I have had my AEM CAI on my 2003 corolla for about 15,000 miles and no problems. I now have 33,000 miles on my car and for the past 2,000 miles the Check Engine Light would come on. I thought it was just an idiot light because my gas tank cap was not fully tightened. So I just reset the ECU by disconnecting the battery terminals. Then I waited a couple of minutes and reconnected the battery terminals. I drove around town for like a month no problems. Then as soon as I go on the highway over 75 mph the light pops back on. I reset the ECU and drove around town no problem. Then I went on the highway again, and again over 75mph the CEL came back on. Now I have been driving with the light on just to see if it will go off, but it hasn't. Could there be something I can do to fix this? I am losing my mind thinking I f'ed up my engine some how by hooking up the AEM intake. I would like to take it to the dealer but forgot how to hook it back up to the stock. If someone has instructions for that it would be greatly appreciated or if someone can tell me how to fix this? I went to Autozone and they did a free diagnosis and that's how I got the code. Their explanation was that it is the CAI causing the light to come on since the sensor is seeing a massive flow at that speed hence setting the light to come on. Thx Anthony

have u done only CAI? i've never heard of it happening b4. if nobody else knows anything, try putting ur stock airbox on, and imitate the scenarios when the CEL cam on with the CAI. see if it replicates itself or not. my 2 cents but i hope someone else has something better.

The only other part I have is a TRD strut bar which wouldnt have anything to do with the AEM CAI. It was weird that it started to happen after like 15,000 miles. It also started to happen right around the 30,000 mile mark. I had a 30,000 maitenance tune up and the next day driving on the highway it began with the CEL light. Now I am paranoid trying to figure out if my performance is down. When I start off I hear a little rattle. Oh yea I have a 5 speed manual if that has anything to do with it.

thx

anthony

main thing thats trowing me off guard is that its throwing an EGR code... im wondering if u might be having any emissions problems. Where di u get the 30k work done at? The dealership I'm assuming?

sorry it was the p0420 code

it was the p0420 code for my cat converter among other things such as air flow sensory...can it be because of the CAI, I am about to disconnect it and just put the stock back on.

yah do that n take it to the dealer. warranty should cover it still

I got the same problem with my TRD intake, too much air, not enough fuel being fed. Took it to the dealer and they said they couldn't do much because its not factory. They just reset it, told me I was running a little lean and gave it back to me. I got the light once right after that, I just reset it and I haven't gotten it yet. I seem to get it when I'm low on gas so I fill up often. I also have the instructions for the TRD intake install if your interested I can email them to you. By the way mine is auto so I don't think its a problem with the cai and 5spd.

thanks alot everyone...yea i also run low on gas alot when it happens...i will take it off and bring it to the dealer...and if you can pls email the CAI instructions to fastpaseo@yahoo.com thx anthony

Hey, just sent you the email. Good luck.

hey wassup guys...damn!! i thought i was the only one this happened to....the crazy thing is that i had my AEM Cold Air in when i had like 7,000 miles on the car and the check engine light went after 30,000 miles....i took it to the dealer and said i voided all warranty with my aftermarket stuff....but before i went there i went to autozone to read the code....and they gave me the same code saying that it had to do something with they catyllitc convertor or something....but after taking it to toyota they checked the codes and said that toyota gets percise codes and said i had alot of problems....they said that all the cylinders where misfiring and some i had catylitic problems....they said the best thing they can do is reset the codes and wait....well they did that and sure enought after a week the light came back on...i had the problem for like 3 months.....the first month the code would just come and go....like it would go on...then go out by itself then about a month it stayed on before i got it checked....after going to toyota and them resetting the codes...i didnt have the money to do what they wanted to do...which is turn all my parts back to stock...it cost to much and all i had was an CAI and a custom cat-back exhaust....my friend and i tried seeing if the sparkplugs where bad...well we disconnected the battery and the spark plugs....we took one out and decided to put it back and drive to autozone to pick new ones anyway whether they were bad or not...well surely i started the car and the light was out...he said if it goes on to try doing that...well its been 5 days and nothing came on and i've been driving the car hard to see if it would....pushing the engine hard and going 100mph....so seems good....try replacing your sparkplugs if they say engine misfiring

if you engine is running lean enought to set the CEL on then its probably your mass air flow sensor thats screwed up. my sis has an 01 corolla and all she did was put a k&n filter in it and its started to run lean and it would hesitate when you first punched it but as ssoon as the rpms got up there it would be fine. decided to try a swap of MAF sensors with my car and sure enough her car ran fine and the light went off... put hers in mine and mine did the same thing hers was doing with the hesitation and all.

I looked up the code p0420 for the vibe..should be simular if not the same,

--Description--


The DTC P0420 Catalyst System Low Efficiency diagnostic monitors the operation of the exhaust system catalytic converter. In order to control exhaust emission of hydrocarbons (HC), carbon monoxide (CO) and oxides of nitrogen (NOx), a three-way catalyst converter is used. The catalyst within the converter promotes a chemical reaction which oxidizes the HC and CO in the exhaust gas, converting the HC and the CO into harmless water vapor and carbon dioxide. The catalyst also reduces NOx by converting the NOx into nitrogen. The powertrain control module (PCM) has the capability to monitor this process using a heated oxygen sensor (HO2S) located in the exhaust stream past the three-way catalytic converter. The PCM compares the signal from the heated oxygen sensor 1 (HO2S 1), located before the catalyst with the sensor 2 (HO2S 2) located after the catalyst in order to determine if the catalyst has deteriorated. If the catalyst is functioning correctly, the HO2S 2 signal will be far less active than the HO2S 1. Both HO2S signals changing at similar rates indicates that the catalyst is deteriorating.

--Diagnostic aids--

Check for any of the following conditions:

A contaminated or malfunctioning HO2S can cause inaccurate sensor readings. For checks of the HO2S refer to Diagnostic Aids in DTC P0130 .
Observe the HO2S 1 voltage and fuel trim readings with a scan tool. If the HO2S 1 voltage is fixed low, while the fuel trim is constantly high, check the mass air flow (MAF) sensor signal circuit for resistance. High circuit resistance can cause the sensor to read a lower volume of air than actual, resulting in a lean fueling condition. This lean fueling condition can cause the HO2S 2 voltage to be fixed low, causing the DTC P0420 diagnostic to fail.
A damaged HO2S wiring harness--Inspect the HO2S wiring harnesses for damage and repair as necessary.
If a DTC P0420 is intermittent, driving the vehicle under the conditions outlined in the Inspection/Maintenance (I/M) section can verify whether the fault is present.

wow thanks for the inform...im not sure but is there a way to or product that can be used to clean the sensor and where exactly would it be located?

you should be able to use some brake cleaner to clean it up