Chrysler Repair: 00 2.5 V-6 .; intermittent miss, code 0401, 4 digit numbers, vacuum leak


Question
QUESTION: we have installed plugs wires rotor egr valve coil pack air and fuel filter small vacuum leak (that was repaired.  we have a periodic miss after 30-40 minutes then drives fine but the engine stays continuously.  what do we need to do?

ANSWER: Hi Debi,
Have you tried for a fault code readout? There is a socket under the dash by the steering wheel into which a fault code reader is plugged to do that. An Autozone parts store will do it for free, usually. Or an independent shop will charge less than $40. Ask for the 4-digit fault code numbers, what they mean, and how to fix and for how much $. Then follow-up with a question telling me the results and we can go from there.
You might try the ignition key to see if faults would readout in the odometer window:"on-off-on-off-on and leave on" doing that in 5 seconds or less elapsed time. Then see if the mileage reading changes to show any 4-digit numbers preceded by a P. Either way, fault codes would be the first thing to find, if any.
When you respond, please explain how long the miss lasts when it begins to happen, and whether there is any rhyme or reason about what goes on just before it starts or just after it stops. A miss can have so many reasons you either have to get a code or diagnose it when it is happening, and having the tools/meters with you at the moment. Are you using cruise control when it happens?
Roland

---------- FOLLOW-UP ----------

QUESTION: Ok we got the code read today and it is as follows P0401.So our next move (besides TNT) should be ? thanks -ed

Answer
Happy New Year, Debi!
May I ask for your help?
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Roland

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Hi Debi/ed,
The 0401 code says that when the controller tests the egr system that the egr valve is not responding properly. I suspect that it does open momentarily, but instead of closing instantaneously it is hanging up slightly ajar which causes the perceptible miss. If it closed quickly during the test you wouldn't notice it.
So you need to try and get it freed up and moving again so that it will open and close quickly smoothly when asked. Another symptom of a sticky valve is occasional difficult starting.  
So check the mechanical function of the egr valve which is located along a small diameter metal pipe that runs from the left exhaust manifold (on the side of the engine facing the front of the car) to the intake manifold area (where the incoming air in the large rubber tube enters the throttle). You will see it just adjacent to the thermostat housing. It is controlled by an electro-vacuum solenoid located on the cylinder head just below the oil filler cap. The two parts of the system are connected by vacuum hoses. Begin by looking to be sure the vacuum hoses are attached and not cracked or leaking. Most likely the valve is the problem.
That valve is metal and has a round fitting with a vacuum hose attached, mounted on the top of the valve, and the round part is attached to the main body of the valve by a sort of saddle.  Inside the open saddle you will see a metal rod (with a slot) that connects the round top fitting to to the valve body. That rod is a stem on the valve and it is supposed to go in and out in response to the engine vacuum which varies with RPM and throttle opening (gas pedal position). Take a spray can of WD-40 or other penetrating lubricant and spray the stem where it enters the valve body (the part mounted to the pipe) and then use a regular screwdriver blade tip inserted in the slot to lever the valve in and out to try and free up its motion. If the valve seems to open (against the action of a spring) and close firmly by the spring action when using the screwdriver blade to facilitate the motion, then you should find the missing has stopped. You can check that the valve stem moves by observing the slot when you rev the engine from idle to 2500 rpm and back to idle. If it still shows the 'miss', then removing and cleaning the interior of the valve, or buying a new one if it seems too crudy and corroded inside, is the next step. Save the TNT, this is not unusual for these valves.
Roland