Back to the check engine light - trouble code 0401 (insufficient flow on EGR). I have 204000 miles on my 1996 SC300. The aforementioned trouble code came on around 188000 miles. Removed and cleaned out the EGR valve, put back on, reset codes, check engine light came back on.
Removed filter from the EGR modulator, cleaned, put back in, reset codes, check engine light came back on. Bought and installed new EGR valve, reset codes, engine came back on.
Bought and installed new EGR modulator, reset codes, engine light came back on.
Cleaned out all EGR related lines/hoses, etc., reset codes, check engine light came back on.
Removed VSV, ran tests as per Lexus repair manual, all passed, reset codes, check engine light came back on.
Removed VSV again since it was the only part not brand new. Noticed a small round metal plate at one end and figured that when I ran battery power to the VSV terminals (one of the VSV tests to check airflow) the small metal plate should have some type of movement from within the VSV, but it did not. After closely examining the VSV I saw where it could be taken apart. So I pried it open and found 1" long solid metal dowel followed by a spring, both covered with soot. Cleaned both parts and the inside of the VSV with throttle body cleaner and dried them off with compressed air. However, when I sprayed the inside of the VSV with the compressed air a third part pops out; another solid metal dowel about 3/8" long which evidently was stuck inside the VSV with soot. Cleaned that part with throttle body cleaner, too. Reassembled the VSV, ran the "battery power to the VSV terminals test" but this time I felt the metal dowels click back and forth when I applied and removed power. Checked the air flow through the VSV as per the Lexus repair manual and noticed increased air flow when there should be and no air flow when there should not be. Put the VSV back on, reattached the two hoses and the power plug, reset the codes, check engine light has not, I repeat, has not come back on. Hallelujah!
I do not know if this will work for all 0401 trouble codes, but it worked for mine.