What does this cost in your state?
California is the costliest state and Arkansas the cheapest; each square shows that state's midpoint of the estimate.
Lower-cost states ($395)MiddleHigher-cost states ($504)
What it shows: CA is the highest at $504 and AR the lowest at $395, across 51 states.
Counts below are complaints filed with NHTSA, not failure rates: a longer bar means more owners reported it.
Is your car affected?
What it shows: The most common band for complaints about this repair is 50,000-100,000 (43%). The biggest difference from all complaints is under 50,000: 32% against 60%.
What it shows: The most common band for complaints about this repair is 6-9 years (44%). The biggest difference from all complaints is under 3 years old: 14% against 40%.
Is it urgent, and what do owners notice first?
507 owner complaints name this part.
Owners say the dealer could not fix or repeat the problem. If it comes back after a repair, ask what was tested before you pay again.
Which trouble codes do owners report?
P0401 Exhaust Gas Recirculation Flow Insufficient Detected leads at 7.
Trouble codes owners quote in complaints about this part. P0401: Exhaust Gas Recirculation Flow Insufficient Detected: 7 complaints (1%).
What do owners say it led to?
Among the 507 owner complaints naming this part, owners most often say loss of power followed.
What owners say happened after the problem. Loss of power: 23 (5%); Engine damage: 13 (3%).
If your car shows the signs above, get it checked before it gets as far as loss of power.
How fast were owners driving when it happened?
55 mph or faster leads at 61%.
Owners reported it most often at highway speed. Tell the shop what speed it happens at, because that narrows the diagnosis.
How serious did it get for owners?
Among the 507 owner complaints naming this part, being towed is the outcome owners report most often.
What it shows: Towed is the largest at 30, followed by Fire reported at 29; the smallest shown is Injury reported at 3.
Which model years show up most in the complaints?
Among the 507 owner complaints naming this part that state a model year, complaints cluster in a few model years instead of spreading evenly.
What it shows: 2017 is the largest at 146 (29%), followed by 2015 at 84 (17%); the smallest shown is 2025 at 4 (1%).
Is this repair covered by an emissions warranty?
Federal rules require carmakers to cover the catalytic converter, the emissions computer and the onboard diagnostic system for 8 years or 80,000 miles, and any part whose failure fails an emissions test for 2 years or 24,000 miles; California requires 3 years or 50,000 miles on every emission part.
| Warranty | Covers | Length |
|---|---|---|
| California, all emission parts | All emissions-related parts | 3 years or 50,000 miles |
| California, high-cost parts | Specific high-cost emission parts listed in the owner manual | 7 years or 70,000 miles |
| Federal, basic | Any part that causes an emissions failure | 2 years or 24,000 miles |
| Federal, extended | Catalytic converters, electronic emissions control unit (ECU), onboard emissions diagnostic device or computer (OBD) | 8 years or 80,000 miles |
Which engine sizes show up most in complaints about this part?
Among 501 owner complaints about this part where the VIN identifies the vehicle, 35% involve engines of under 1.6 L, against 11% of complaints about all the parts we track.
What it shows: 2.1 to 3.0 L is the largest at 39%, followed by under 1.6 L at 35%; the smallest shown is over 5.0 L at 5%.
What do emissions repairs cost?
Among 46,033 California vehicles repaired to pass a Smog Check in 2025, 39.1% cost over $650 to fix and the average bill was $757.
What it shows: Over $650 is the largest at 39.1%, followed by $1 to $100 at 13.1%; the smallest shown is $501 to $650 at 8.4%.
If my car fails smog, how much of this repair must I pay, and does California help?
California caps required Smog Check repair spending at $650 through a repair cost waiver and its Consumer Assistance Program pays up to $1,450 of repairs for qualifying owners of 1996 and newer cars, so on a typical $455 egr valve replacement the program would pay $364 and the owner $91.
| Rule | Amount | What it means at $455 |
|---|---|---|
| CAP repair assistance, model year 1976 to 1995 | up to $1,100 | you pay 20% up to $1,375 of repairs, then everything above $1,100 |
| CAP repair assistance, model year 1996 or newer | up to $1,450 | On a egr valve replacement at $455 the program pays $364 and you pay $91 |
| CAP vehicle retirement | up to $2,000 | paid instead of repair when you retire the car |
| Repair cost waiver line (every Smog Check failure) | $650 | A egr valve replacement at $455 is under the line, so no waiver |
| Roadside re-failure within a year, model years 2000 to 2006 | 17% after passing, 35% after failing first | 7,886 cars checked in CY 2017-2018 |
After a failed emissions test, who can repair it, and what do repairs cost?
Maryland lists 135 certified emissions repair facilities and New Jersey 332, while Texas inspectors logged about 21,000 emissions repairs costing $3.7 million across its two inspection areas in 2024 and 2025, with a median repair cost of $25 to $299 by category after dropping zero and over-$2,000 entries.
| Program | What the public record shows | Count or figure |
|---|---|---|
| Maryland certified emissions repair facilities | 13 counties; most in Baltimore 31, Montgomery 24, Anne Arundel 17 | 135 facilities |
| New Jersey emission repair facilities | 218 also run private inspections | 332 facilities |
| Texas program evaluation, repair records | repairs logged by inspectors, Dallas-Fort Worth and Houston areas, 2024 and 2025 | about 21,000 repairs, $3.7 million |
| Texas repair cost per repair (median and mean ranges) | by repair category, after dropping zero entries and costs above $2,000 | median $25 to $299, mean $82 to $415 |
| Texas repair records logged at zero cost | inspectors enter the cost by hand; the report warns of entry errors | 68.1% of records |
Has the replacement part I am buying been recalled?
NHTSA lists 1 equipment recalls that name egr valve since 2015 (engine and vehicle speed control), covering 2,217 items sold as parts rather than whole vehicles; the largest, by Borgwarner in 2022, covered 2,217.
| Year | Maker and product | NHTSA component | Defect | Items |
|---|---|---|---|---|
| 2022 | Borgwarner: Egr Valve | exhaust system emission control | certain Exhaust Gas Recirculation (EGR) valves with part numbers LX6E 9D475 AB and 05281255AK. | 2,217 |
Has this part been recalled abroad on cars that may share it?
Manufacturers filed 8 foreign recall campaigns that name egr valve with NHTSA since 2015 (matched by the filing text); the latest, from Hyundai Motor America in 2024-04.
| Filed | Manufacturer | Foreign recall no. | What the filing says |
|---|---|---|---|
| 2021-12 | Toyota Motor Corporation | 270 | Enclosures Foreign Safety Recall Report Date: December 3, 2021 Foreign Safety Recall / Other Safety Campaign Report Subject: EGR issue on certain Toyota and Lexus vehicles 1. |
| 2017-12 | Toyota Motor Corporation | 223 | Enclosures Foreign Safety Recall Report/Other Safety Campaign Report Date: December 1, 2017 Foreign Safety Recall/ Other Safety Campaign Report Subject: EGR valve issue on certain Toyota Auris, Avensis, RAV4 and Verso vehicles 1. |
| 2020-06 | Volvo Car | 114 | Volvo Cars will update concerned vehicles with improved soot reducing software and re-build EGR circuit, cleaning of TMAP and EMAP. |
| 2024-04 | Hyundai Motor America | 094 | Description of the defect/noncompliance: The exhaust gas recirculation ("EGR") valve assembly in the subject vehicles may contain a sensor that was contaminated with solder flux during supplier manufacturing, which could potentially result in an electrical. |
| 2024-04 | Kia America. | 089 | Eileen Sullivan Associate Administrator for Enforcement National Highway Traffic Safety Administration Attn: Early Warning Division (NVS-217) 1200 New Jersey Avenue, SE, Washington, DC 20590 VIA EMAIL Re: TREAD Act Reporting of a Foreign Country Recall 2024MY. |
| 2022-05 | Mitsubishi Motors. | 075 | Defect description: Due to inappropriate software programming of the engine ECU, excess carbon deposits could accumulate in the EGR (Exhaust Gas Recirculation) system. |
| 2016-04 | Toyota Motor Corporation | 062 | Description of Problem: The subject vehicles are equipped with a 6AR-FSE engine which contains an EGR (exhaust gas recirculation) system. |
| 2020-03 | Volvo Car | 057 | Volvo Cars will update concerned vehicles with improved soot reducing software and re-build EGR circuit, cleaning of TMAP and EMAP. |
How many recalled cars are actually fixed, so should I check mine?
Across 6 NHTSA recalls that name egr valve filed 2015 to 2024, 83.4% of the 156,405 recalled vehicles had been repaired after 8 quarters, against 66.2% for all recalls, which leaves about 26,031 vehicles still carrying the defect.
| Year | Vehicles | Recalled vehicles | Repaired | Component |
|---|---|---|---|---|
| 2019 | Ram 1500 | 107,980 | 82.2% | exhaust system emission control |
| 2020 | Jeep Grand Cherokee | 28,884 | 83.7% | exhaust system emission control |
| 2024 | Hyundai Venue, Elantra | 13,511 | 89.1% | exhaust system emission control |
| 2020 | Freightliner Sprinter 2500, Sprinter 3500; | 4,424 | 92.7% | exhaust system emission control |
| 2022 | Jeep Grand Cherokee 4xe, Grand Cherokee; | 1,308 | 77.8% | exhaust system emission control |
| 2022 | Bmw 540d | 298 | 94.6% | exhaust system emission control |
Does my county fall under federal smog rules or breathe unhealthy air?
EPA's Green Book lists 203 counties as currently nonattainment for ozone or fine particles, home to 39.6% of U.S. residents; the shares run highest in DC, NJ and CA (100.0%, 100.0%, 94.9%).
| State | Share of residents | Nonattainment counties |
|---|---|---|
| DC | 100.0% | 1 |
| NJ | 100.0% | 21 |
| CA | 94.9% | 38 |
| MD | 88.4% | 12 |
| DE | 81.6% | 2 |
| UT | 79.4% | 7 |
| NV | 73.0% | 1 |
| IL | 71.7% | 11 |
| AZ | 68.5% | 3 |
| CO | 68.0% | 9 |
| Median state | 0.0% |
If this part was recalled, is the repair free?
Federal law (49 U.S.C. 30120) requires a maker to fix a recalled defect without charge for cars first bought within 15 calendar years (tires within 5), and NHTSA lists 9 recall campaigns for parts matched to a egr valve replacement since model year 2015, covering about 248,592 vehicles.
| Rule or count | What it says |
|---|---|
| Age limits | The free-remedy duty does not apply to a car first bought more than 15 calendar years, or a tire first bought more than 5 calendar years, before the recall notice. |
| Failure to fix | A repair not done adequately within 60 days of presentation is prima facie evidence of failure to repair within a reasonable time; the maker must then replace the vehicle or refund the purchase price less depreciation. |
| Free remedy | A maker must fix a recall defect without charge. |
| NHTSA recalls matched to a egr valve replacement since model year 2015 | 9 recall campaigns covering about 248,592 vehicles |
Which emission standard was my car certified to?
EPA's certification records show 100.0% of model year 2014 light-duty carlines certified to the older Tier 2 exhaust standard and 79.1% of model year 2026 carlines certified to Tier 3 Bin 50 or cleaner, so the catalytic converter and sensors a car needs depend on its model year (one count per carline, not per car sold).
| Model year | Tier 2 (older standard) | Tier 3 Bin 70 to 160 | Tier 3 Bin 20 to 50 (cleaner) | Tier 3 Bin 0 (zero emission) |
|---|---|---|---|---|
| 2014 | 100.0% | 0.0% | 0.0% | 0.0% |
| 2016 | 95.6% | 3.1% | 1.2% | 0.1% |
| 2018 | 3.1% | 82.4% | 12.8% | 1.8% |
| 2020 | 2.4% | 69.8% | 24.7% | 3.1% |
| 2022 | 0.2% | 53.2% | 38.3% | 8.3% |
| 2024 | 0.3% | 34.5% | 43.5% | 21.7% |
| 2026 | 0.1% | 20.7% | 48.1% | 31.0% |
Is it recalled or covered?
| Recall number | Vehicles | Cars recalled | What the recall says |
|---|---|---|---|
| 19V-757 | RAM 1500 2015–2019 | 107,980 | Combustion in the intake manifold can increase the risk of a fire. |
| 26V-122 | Ford Bronco 2025; Ford Bronco Sport 2025; Ford Escape 2025 and 6 more | 47,804 | An unexpected loss of drive power increases the risk of a crash. |
| 18V-755 | BMW 535d 2015–2016; BMW 328d 2015–2018; BMW X5 2015–2017 and 2 more | 44,368 | The melting intake manifold can increase the risk of a fire. |
| 20V-699 | Jeep Grand Cherokee 2015–2019 | 28,884 | Combustion in the intake manifold can increase the risk of a fire. |
| 24V-308 | Hyundai Venue 2024; Hyundai Elantra 2024; Hyundai Kona 2024 | 13,511 | A loss of drive power increases the risk of a crash. |
| 20V-078 | Mercedes-Benz Sprinter 1500 2019; Mercedes-Benz Sprinter 3500 2019; Mercedes-Benz Sprinter 2500 2019 | 4,424 | If the connecting screws are not properly tightened, hot exhaust gases may leak from the EGR pipe, increasing the risk of a fire. |
| 22V-284 | Jeep Grand Cherokee 4xe 2022; Dodge Durango 2021; Jeep Grand Cherokee 2021 | 1,308 | An unexpected loss of drive power increases the risk of a crash. |
| 22V-614 | BMW 540d 2018 | 298 | A melting intake manifold increases the risk of fire. |
1 more recalls name this part, on smaller fleets. The car finder at the top checks yours.
A bulletin is a repair procedure a maker sends its dealers, not a safety defect: if your maker is listed, ask the dealer whether one covers your car and quote its number.
| Maker | Vehicles | Bulletin number | Date | What it says |
|---|---|---|---|---|
| Hyundai | Sonata 2020–2021 | 23-EE-009H | Aug 21, 2023 | This bulletin provides warranty procedure for EGR Valve replacement related to DTC P0401 EGR Flow Insufficient on 2020 and 2021MY Sonata (DN8a) equipped with 2.5 GDI Vehicles. |
| Nissan | Rogue 2023 | NTB23-015 | Feb 23, 2023 | Mil on and dtc P0401 stored in the ecm if you confirm The Malfunction Indicator Lamp (MIL) is ON and DTC P0401 (EGR System) is stored in the ECM. |
| Chevrolet | Volt 2016–2019 | 21-NA-116 | Feb 3, 2023 | This service bulletin provides a service procedure to replace the EGR to correct a customer concern of a MIL illuminated. |
| Nissan | Altima 2019–2022 | NTB22-097 | Nov 4, 2022 | DTC P0404 stored in the ecm at temperatures below 32 F if you confirm dtc P0404 (EGR A CONTROL) is stored in the ECM at temperatures below 32 F. |
| RAM | 3500 2015–2018; 1500 2015–2018 and 1 more | 85049 | Aug 8, 2022 | The bulletin file gives no description beyond its title (cooler). |
| Nissan | Sentra 2020–2022 | NTB22-067 | Jul 29, 2022 | Mil on with dtc P0401 AND/OR P0404 stored in the ecm if you confirm The MIL is ON and DTC P0401 (EGR A FLOW INSUFFICIENT) and/or P0404 (EGR A CONTROL) is stored in the ECM. |
54 more bulletins name this part; the car finder at the top checks yours, and the NHTSA bulletin file linked below lists them all.
Manufacturer warranty extensions naming this part (3)
| Maker | Vehicles | Date | Notice number | What the maker extended |
|---|---|---|---|---|
| BMW | 535d 2014; X5 2014 | Sep 3, 2025 | B011018 | N57T diesel engine auxiliary EGR cooler. |
| BMW | 535d 2014; X5 2014–2015 | Dec 17, 2018 | B011418 | N57T engine exhaust-gas recirculation valve. |
| RAM | 1500 2013 | Nov 3, 2017 | 09-010 | Exhaust gas recirculation valve causing engine surge or hard. |
What do owners say?
4 complaints quoted word for word, each with its NHTSA number.
I owned this car for less than 2 years and it's already costing $700.00 to have a EGR valve failure.
The dealership charged me $1,400 for a repair involving new gaskets and the EGR cooler.
Diagnosis is that I need a new EGR valve and new engine $13,000.
The EGR Valve, Diesel Particulate Filter, and Intake Manifold failed at 88k miles.
Check your car
EGR valve replacement costs $270–$640 on a gas engine at a $120/hr shop: the valve plus 1.0–2.0 hours of labor. A diesel valve runs $430–$1,060 because the job takes 1.5–3.0 hours. Of 632 NHTSA complaints naming this part, recall mentioned was reported in 39%.
Chevrolet Volt leads EGR complaints, and GM bulletin 21-NA-116 covers 2016-2019 models
The Volt accounts for 169 of the EGR complaints, far more than any other model. Complaints peak on 2016-2018 model years, at a median of 60,000 miles.
GM bulletin 21-NA-116 gives a service procedure for replacing the EGR on 2016-2019 Volts to fix an illuminated check-engine light. If your Volt matches, bring up the bulletin number when the dealer quotes the job.
EGR-related trouble codes P0401 and P0404 have their own Hyundai and Nissan bulletins
Hyundai bulletin 23-EE-009H gives a warranty procedure for replacing the EGR valve on 2020-2021 Sonatas that set code P0401. Nissan bulletin NTB23-015 addresses P0401 on the 2023 Rogue. NTB22-067 covers P0401 and P0404 on 2020-2022 Sentras, and NTB22-097 covers P0404 set at temperatures below 32 F on 2019-2022 Altimas. If your scan shows one of these codes, the matching bulletin may point to a different fix than a new valve.
EGR failures are reported mostly at highway speed, and 39 reports mention fire
Owners who were driving when the EGR failed reported a median speed of 60 mph, and most of those failures happened at highway speed. Only a small share needed a tow, so most cars still made it to a shop.
A report does not prove the EGR caused the event. Even so, these fire reports come mainly from the same diesel models whose recalls name fire risk.
Most EGR complaints name a dealer, and the Nissan Rogue shows how add-on work inflates the bill
A 2023 Rogue owner said the dealer wanted fuel injectors and the EGR valve replaced, "totatling almost 5,000 after just paying $1,700 last month." (NHTSA complaint #11697206)
By comparison, the calculator puts a diesel EGR valve at $430–$1,060 at an independent-shop rate. At a $175/hr dealer rate, a gas valve comes to $325–$750. A quote well above those ranges almost always includes parts beyond the valve.
Sources
Data shown on this page
- NHTSA owner complaint file (2015-2019 · 2020-2024 · 2025-2026) file downloaded 2026-10-05
- NHTSA recall file file downloaded 2026-10-05
- NHTSA service bulletin file (2015-2019 · 2020-2024 · 2025-2026) file downloaded 2026-10-05
- CalcScrape calculator model scaled by BEA Regional Price Parities data from 2024
- U.S. Code of Federal Regulations, 40 CFR 85.2103, and the California Air Resources Board warranty fact sheet file downloaded 2026-10-05
- NHTSA owner complaint files with VINs decoded by NHTSA vPIC data from 2025
- California Bureau of Automotive Repair, Smog Check Executive Summary Report 2025 data from 2025
- California Bureau of Automotive Repair: Smog Check Reference Guide, Consumer Assistance Program repair assistance page, and 2019 Smog Check Performance Report data from 2025
- Maryland Department of the Environment (opendata.maryland.gov 7gas-4kz4), State of New Jersey open data (9qpt-bnm4), Texas Commission on Environmental Quality, Evaluation of the Texas Vehicle Emissions Inspection and Maintenance Program (2026) data from 2026
- NHTSA Office of Defects Investigation, Foreign Campaigns (filings under 49 CFR 579.11, public API) file downloaded 2026-10-05
- NHTSA Office of Defects Investigation, recall quarterly reports (basis of the Annual List of Recall Completion Rates) file downloaded 2026-10-05
- EPA Green Book, Currently and previously designated nonattainment areas by county; county population from the 2020 Census file downloaded 2026-09 (EPA export 2026-09-30)
- 49 U.S.C. 30120 (Remedies for defects and noncompliance), text via Cornell Legal Information Institute; NHTSA recall campaigns data from 2026
- U.S. EPA, Annual Certification Data for Vehicles, light-duty vehicle models 2014-present (exhaust standard of every certified carline) file downloaded 2026-10
Terms: US government data, public domain.
Observed: records as filed; owner reports are unverified and are not failure rates. Modeled: our estimate, not a quote. Rule: a published legal rule, not a measurement; whether it covers a given repair depends on the car and the facts. Derived: computed from the records; an association, not a cause.
Owner complaints quoted
What is our own estimate
The price range comes from our calculator's formula. Its parts prices, labor hours per job and shop-rate tiers are CalcScrape estimates, not a published price dataset. Checked against RepairPal's range ($489–$632) on 2026-10-06: our default's midpoint is 19% below the middle of that range. Methodology