MIL Service Engine Soon Telltale is Illuminated With DTC P0401

Some customers may comment that the (MIL) SERVICE ENGINE SOON telltale is illuminated with DTC Pie present or stored in PCM malfunction history.

This condition may be caused by incorrect EGR valve being installed on vehicle. The EGR valves used on 1996 - 1999 model year vehicles have a different flow rating than EGR valves used on 2000 - 2001 model year vehicles.

Verify that the correct EGR valve is installed. If necessary, install correct EGR valve by using procedures in this bulletin.

1. Inspect part number stamped into the top of EGR valve. The correct EGR valve part number for a 1996 - 1999 model year Saturn vehicle is 21006601.

•	If part number on the top of EGR valve is 21006601, refer to EGR System Diagnosis in the Powertrain Controls section of appropriate model year Service Manual for information on DTC P0401.

•	If part number on the top of EGR valve is not 2106601, proceed to next step.

2. Remove fresh air hose.
3. Disconnect EGR valve wiring harness terminal and airlet tube.
4. Remove EGR valve attachment bolts and valve assembly .
5. Inspect cylinder head and adapter passages for excessive carbon deposits. Deposits can be removed using a screwdriver.

Important: The part number stamped on the top of the EGR valve will differ from the kit part number. Before installing new EGR valve on the vehicle, make sure that part number stamped on the EGR valve is 21006601.

6. Obtain new EGR Valve Service Kit (P/N 21008421) from parts Department.



7. Install new EGR valve gasket and valve.

Important: Make sure gasket is installed correctly or vacuum leak will occur.

8. Install EGR valve attachment bolts.

Tighten
Tighten nut to 25 N·m (19 lb ft)

9. Connect EGR valve wiring harness connector.
10. Inspect air inlet tube. Attach air inlet tube and tighten clamp.
11. Install fresh air hose.
12. Start engine and inspect for exhaust gas leaks and check for DTCs.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for J6270 (EGR valve and/or gasket replacement).