egr probs again sorry

[deeznutts77]

ok i did all the cleaning of egr stuff like jerry said and still get egr flow malfunction. also got a New" used " "good" egr and mod valve. still reves at stop lights and after one or two minuts driving cel on so wont pass inspection. plz help cause i love this little truck. 1.6 16v with header cold air intake 96 in ny not the city lol

[jtgh]

96' 1.6L 16v Kick .

now , can you tell the DTC (diagnostic trouble codes ) that is it is throwing.?

po400 is egr. but throwing others? means that EGR is ok and that the others are PRIMARY.

pull the codes, and all pendings too.
do not pull the codes ,if you just reset all codes,

no do not do any more resets, ok?
just drive it, and pull all codes and lets fix the real problem

EGR monitor only works correctly on a good running engine.
if you have another major problem then the EGR is only a destraction.

OEM FSM. troubleshoot EGR last, but always clean it first.

next:
how does car start ,run idlle , hot and cold.
how is the power.?
any bogging , or back firing or the like?

rent a code reader , at least. and pull your own codes. (buy tool for $50, rent for $5)
do not reset, and do not pull the battery terms.
doing so, hides the problem from you and me, and not the smog man.


you do know about the hidden , oriface in the TB ,throttel body neck ,right.
you saw my green tie wrap, in the bottom photo, right?
this spot loves to clog.


if the engine has a problem with vacuum, caused by anything bad, this will cause
EGR monitor to lie its buns off.

EGR monitor , works by monitoring vacuum as the valves is opened.
Misfire, leaking valves, air leaks,and many things can mess up the EGR test.
and of course a stuck open or closed EGR.

tell us more.

[deeznutts77]

ok down the list
only one code egr flow malfunction (think 0400)
no pending
next
starts great idels good till i drive than all h3ll , if i shut if off go in store and restart good till i stop at light
plenty of power
no bogging or backfiring
yup cleaned all yes all
i sucked all hoses to see if leak and propane around the motor and no leaks. i have an electric fan so it didnt blow away when runnin

[jtgh]

till i drive than all h3ll
explain HE,double tooth picks. to me.

just the CEL or is DRIVEABILITY effected in somway.?

if just P0400 and no other symptoms, then lets work on that EGR.

[deeznutts77]

h3ll=hell and after driving startup is good and ideling
drives great no hesation nothing i can get rubber in 2nd it drive awsome just that cel light and egr prob

[jtgh]

basic path for egr:
1: make sure the valve is not stuck open with carbon chunks or a jammed open siezed valve.
2: then conduct the stall test. ( with fingers (burn, ouch)or with a vacuum hand pump
apply 10 inches vaccum at EGR main, nipple. valve opens engine stalls,(or almost)

if you can get this far good. if it engine down stall then the EGR path is blocked.
if it does, you might have troubles with the EGR mod valve or VSV valve .

can I presume your car still has a CatConverter.? and that it is not rodded out or blown out ?

I think CATCON is ok as that would set P0420 or near. (lazy cat fail)


see green tie wrap on lower 2 photos.
this is an oriface that loves to clog or neck down.


if you fail the stall test , above.
consider this path:
http://carfix.stufftoread.com/sensor...6L-plumb1w.jpg
the exhaust is origionalted from the exhaust manifold , it then passes thru a special egr port on the head.
this port passes thur a cast in the aluminum of the head all the way over to the EGR valve ID. #1.
see two holes.
those holes are exhaust IN, and the other is EGR out to to tube #9

those two holes sometimes need to be rodded out with a flex cable .
a cable from a speedo works best but any steel flex cable attached to a drill.

next is the #9 tube.
last is the oriface i mentioned, above.
there are 4 thing total to clean.
most fails are cured by that.

1; head tunnel.
2: egr valve.
3: egr tube 9
4: Egr TB orifice ,port.

I hope this helps.

if the above dont,we will have to the more difficult ,live EGR test.

[deeznutts77]

ok did the ouch test, that is what i call it and it almost stalled i let go.
egr in new used and i cleaned it b4 i put it in and i have a cat and it is hollow but it was runnin fine with no lazy cat codes or any probs till the egr stuff lately. i cleaned the pass through the head and the tube and the little "cap" on top of the tube where it goes in the intake. i did the vsv valve test it was shut till 12v and out the bottom

[ranger88den]

Modulator?

[deeznutts77]

mod valve on top of egr?

[jtgh]

no cat, is a hard row to hoe.

see ,the exhaust back pressure , entering on the bottom of the mod valve must happen. (default is max EGR flow, unless back pressure happens, "mod valve rules")
this takes plenty of back pressure.1-6 psi .

the cat , creates most of that back pressure.

get discount cat and put it on. $59

The P400 conditions: Software monitor
2 tests, one cruising and 1 decelerating. , min, conditions below.
> 158deg F. coolant temp.
> 14 deg F AIR intake temp
rpm 1400 to 3000 . see AT/MT rules.
12.5 to 31% engine load range.
time from start engine 240 sec. to 290 sec. each test.
speed >= 30kmh, 19.mph. min. and 46km/h test 2.
test 1 must pass , 7.4 to 23 mmHG change
test 2 must pass, 35-100 mmHG change

the key here is the change , the ecu must see a change in the range shown.

full details here;
http://service.gm.com/gmspo/mode6/pd...acker_1.6L.pdf

hope that helps.