EGR valve error code P0400

[thefunniefarmer]

I have no idea what I'm talking about so please bare with me.

We have a Corolla Verso T180 D4D bought new in 2006.  We were sold the car as a family car, which was ideal.  It ran like a dream until we started having problems with the engine maintenance lights coming on which showed a fault with the EGR valve, around April 2008.  These problems dragged on, with the car going in to limp mode, until finally the EGR valve was replaced.  However, this did not resolve the problem and in 2011 the engine was stripped down.  We were told on this occasion that there was an inherent defect with the engine (model not made anymore) and that this couldn't happen again.  And it didn't, until Friday.

Engine light on, 10 days after last service and MOT.  Limped to Toyota main dealer where we are back to the error code of P0400 the dreaded EGR valve. We've been quoted £452.65 to replace the EGR valve and clean the mainfold but warned that the engine may need to be de-coked at £2100.

To say we're are unhappy would be an understatement.  We have a FSH, whilst the car is 10 years old it has a very low mileage.

Has anyone had experience of this?  I have a case logged with Toyota GB as we have been told back in 2011 that this is an inherent defect.

Any advice would be gratefully received.

[Mike169]

Hi Emma.

Reading your unfortunate post the part that says this couldn't happen again I am reading this as this couldn't happen again as they changed the design of the engine but unless they changed the design of your actual engine which I doubt then yes it will happen again, that is how I see it, before any expensive repairs i'd be tempted to put a can of this 

https://www.google.co.uk/search?q=bg244&ie=utf-8&oe=utf-8&gws_rd=cr&ei=S8nmVtHbJ8fnUqSPgNgI

in your fuel tank and see if it helps at all and to put a can into your fuel tank every year to help get all the carbon from the internals of your engine. EGR valves coke/carbon up and generally don't need changing but decoking and is a relative easy job

https://www.google.co.uk/search?q=Toyota+T180+EGR+valve+cleaning&ie=utf-8&oe=utf-8&gws_rd=cr&ei=-8rmVrDnGcTWU-GKrfgH

Myself personally I use the expensive diesel which has more cleaning agents in it which equates much the same as using the BG244 I mentioned but perhaps I am lucky as my car is a bit newer and the faults were attended to by the time I bought it but if you used the dearer fuel I think you would get less problems if you aren't using it already?

Here is a real heavy duty way to clean the internals of your engine and myself I would go down this route before thinking having new parts fitted or the engine stripped down

https://www.google.co.uk/search?q=terraclean&ie=utf-8&oe=utf-8&gws_rd=cr&ei=MczmVpzOCMecPuPYqrgK

All just advise and I welcome to read your reply.

Mike.

 

[thefunniefarmer]

Thanks Mike.

 

I've looked at the BG244 product and spoken to the UK distributor who seem to think that a full air intake service (!?) is needed rather than just the BG244 in the tank. 

[Mike169]

Hi Emma.

Yes you are right in what you say about the BG244 and there are other products that do the same but the last link I sent, Terraclean is a sensible option but no promises it will fix your problem but personally I would give it a whirl as basically it is a heavy duty version of doing the same job and I welcome input from other TOC members on their thoughts on the matter.

Emma, basically your vehicle is clogged up and be it you have your engine dismantled to chip away at the carbon or you go down the route of a cleaner spirit instead it's your call, if your vehicle is used for short runs it will be much more likely to clog up if it's not being used on a motorway or similar and giving it a bit of wellie on a regular basis preferably on a weekly basis.

EGR valves are a pain!

Mike.

[thefunniefarmer]

A pain indeed!

I have ust spoken to the local Terraclean agent and it's a much more reasonable price and although no guarantees it will resolve the problem I think it's worth a go.

However, I will give Toyota GB the opportunity to respond before doing anything.  Fortunately I have access to another car.

Thanks again Mike

[thefunniefarmer]

Forgot to mention that the Terraclean chap would clean out the EGR valve first

[Mike169]

Hi Emma.

As a matter of interest can I ask what price you have been quoted by the Terraclean agent?

On the clogging up bit I have read quotes of 'drive it like you stole it' and similar just to blow all the muck out the back which makes the purpose of the EGR valve a bit questionable. Some people block them off, kits for less than a tenner are available from Ebay/Amazon and easy to fit, some swear by doing it, others say leave the set up alone and leave the kits on the shelf (It's only a blanking off plate)

Mike.

[thefunniefarmer]

They have quoted £60 to clean the EGR valve and £90 to do the TerraClean

[Mike169]

Hi Emma.

I'd say go for it £60 to clean the valve is a lot cheaper than fitting a new one and like I said before they only need cleaning anyway and £90 is a lot less than I thought it would be for the Terraclean bit and if it is successful in your case i'd consider having it done at regular intervals.....please do let us all know

a) what you decide to do and

b) the outcome.

Good luck!

Mike.

[Heidfirst]

6 hours ago, thefunniefarmer said:

.  We were told on this occasion that there was an inherent defect with the engine (model not made anymore)

the Corolla Verso T180 used a 2AD-FHV engine & I am 99.99% sure that engine was in production (but maybe not for the UK market, which would be a marketing decision) well past 2011.

The Corolla Verso of course was replaced in 2009 by the Verso & this was also available with the 2AD-FHV.

[thefunniefarmer]

Just had word from the garage - EGR valve cleaned out and Terraclean carried out. "Running like a dream" were the exact words! So relieved, can't wait to get it back.

Thanks for all the advice

[Mike169]

Hi Emma.

What great news to read your car is running sooooo well.

I am sure you can appreciate sometimes suggestions are a bit of a shot in the dark and advise offered with all good intensions and fingers crossed advise offered doesn't just end up wasting your money, awesome to see it all come together in the end.

Maybe in say 3 years time if you still have the car then have the same thing done again before it actually breaks down, cheaper in the wrong run.

Mike