Since I've basically replaced every part of the EGR system with brand new OEM parts and have nothing to show for it, other than a hole in my wallet, where do I go from here? Any advice from Toyota techs would be appreciated!
Yes, checked and cleaned the vacumn lines, throttle body and intake with wire brush and throttle body cleaner.
And update: It looks like the tech who replaced the VSV reversed the vacumn line connections. I corrected this and so far so good. Will report back after so more km on the odometer.
Did you troubleshoot the system according to the FSM (Factory Service Manual)? You probably could have saved yourself a bunch of money, even after you pay for the manual.
Without being there, and based on your description, I agree with the guy above that mentioned carbon build-up. There are very small passageways that can get clogged up, causing the modulator to work incorrectly, creating the "insufficient EGR flow" problem.
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