Cataclean and EGR Clog Codes

Looks like you are in a CARB state.

The $600 repair would most likely not be legal in your area.

Try to source a new OEM.

Magnaflow is expensive but a nice boost in power for sure over OEM.

I would keep using your car until its time to smog, stop resetting the P0420 code and a month before the smog, use cataclean.

For now see if any dealers have an OEM cat in stock, if not they will require a payment in advance for the order and it will be on backorder with no ETA most likely.

 

I was wondering about that. I would not really have expected the firmware update to make a P0401 go away.

I know that they did include updating to that firmware rev in a TSB about changing the EGR valve. But they also update to the same firmware rev in a different TSB about the intake manifold. The EGR TSB doesn't say you should also change the manifold, and the manifold TSB doesn't say you should also change the valve. They just both say you ought to have the newer firmware rev.

That makes me think there isn't anything about the new manifold or the new valve that the new firmware is absolutely specific to, but probably the new firmware has some improved control ideas in it that are worth having.

I wouldn't call it wasted money; firmware updates usually contain improvements worth having. But I'm not surprised it wasn't a magic P0401 fix.

You said the valve and cooler are a month old. Were they new? If used, was the ski jump in the valve checked?

Were the EGR passages in the intake manifold cleaned?

There's an active test described in the P0401 workup section. If you've had a chance to do that, what happened?

 

The ski jump in the valve should be fine if the valve was new. In a used one it could be mashed. If you want to see what that looks like, you could search here for those terms; I don't think we discuss other ski jumps all that often, so you should get threads where it's described.

 

That could be real, but its not sold by them so I would be cautious.

Also you only need the front half not that complete one, also you may have the heat exchanger so that is not the right part.

 

You do not need to replace the heat exchanger, I did not when I used the Magnaflow #5631455

Previously I posted the model # wrong.
It is 5631455 not 5681455

 

Heat exchanger is another term for them same thing, heat recirculates with it.

Just go to Magnaflow and enter your cars details and it will show the right one for your car and state.

The picture you showed does not have the heat exchanger.

 

This may be the one for you if you want a direct fit and you do not have to weld it.

My installer welded mine anyway and I would say to do that also.

You piece it together just make sure you enter all your info in the website or call them and ask for correct and cheapest way to go about it.

Lucky for you this part pictured is the same part I have, only thing is they market it differently and charge me double because I am in California.

 

I have been there and done that.

Replaced the A/F sensor on the manifold
Replaced the downstream O2 sensor on the cat and the issue is the cat.

P0420 will keep coming back.

These things only last about 10 years.
Time to swap it out and bite the bullet.

Yes the Magnaflow will increase the performance because the air flow is better.

If you were not in a state where they car about it, then you could actually purchase a cheap cat like most of the users here.

Shortly down the line, that cheap cat has no more life and gives out.