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Yeah this will be the rebirth of the 1.6 bros. I am going to get my baby back up and running too. I also have been neglecting the forum. But mainly just because of time. But glad to see you haven't given up on it.
I've been fighting a P0401 code for a good while that prevented me from registering my car. I replaced the EGR valve but that didn't fix it. After much research I figured that the port within the intake manifold, that leads to the EGR, was clogged so I decided to clean it out.
The throttle body didn't look too bad but cleaned it regardless.
The intake manifold though, looked filthy. I didn't make time to clean it out as I'd rather take it off to clean it but you can see the port I needed to clean outlined in red.
The deposits you see in there are about 180,000 miles worth but I'm still going to look into a catch can. Even after I cleaned out this port I still had the P0401 code. After a lot of head scratching and more research I realized that the EGR plate was the cause of my issues. I've rationalized that when I put on the block off plate years ago, it didn't seal properly thereby letting a small amount of air through. Enough so that the EGR valve could still read something. Many years and miles later the port was truly sealed with a lot of carbon deposits. I forgot to take one showing all the deposits in there but this is one after I removed the big chunk blocking the hole.
If you're fighting a "low flow" EGR code and you have a block off plate, this might be the source of your struggles. Now I need to go find me a stock EGR pipe so I can cut it down to size and install a filter on it so the EGR valve can function properly.