EGR Cleaning - The HORROR

[libbybapa]

When I was driving home last evening the CEL came on. All other gauges and operation appeared normal so I continued home. I checked the code and it was "Area 51" (the aliens invaded...) indicating the EGR system. After perusing JTGH's excellent site I came to the conclusion that I have the MOST HORRIBLE intake manifold as pictured here (picture borrowed from JTGH):



I reset the CEL and it has not yet come back on. I also pushed the diaphragm on the EGR and the engine idle changed slightly, but not much. I must assume I have a blockage.

What problems am I going to cause to my engine by running as is for a little while? I've removed the intake manifold before and so know the pain involved there and would like to avoid that if possible. I've been considering pulling the EGR valve and fitting a small piece of hose into each of the EGR tube openings and then alternating between filling with carb cleaner, letting it soak and blasting it out with compressed air. Thoughts?

Andrew

[jtgh]

no damage.
if , car gets good MPG.
if mpg goes to 15 or so, then you are in LIMPHOME,
and that burns up manifolds (cracks them) and melts the honeycomb in the CAT.

it is plugged for sure

but id check the easy places first.
the valve on rear.
the ports on under said valve.
for clear , some blow air into them with shop air to see if its free.

the left port goes to the EXH #4 pipe on header.

im sorry if your hidding tubes are clogged, id not wish that on anyone.
dirty little buggers , hidden so well
and that photo is from another nice poster.

cheers

car will fail smog but you know that.

[Richard Craneum]

looking at my Tracker and the EGR Valve...

I was wondering. What about making a hole on the exhaust manifold, tap and thread a fitting to run a metal flex tube like is done on the 3.4 L V6 GM engines to an adapter by the EGR, some like a machined Plenum, like a Carb Spacer. Therefore sealing that passage. Is too much work for some simple.

I am a maintenance type of person and always looking for ways to maintain and up keep my equipment. In case the tube gets clogged it can be easily removed and cleaned accordingly.

[libbybapa]

I think adding a threaded plug to the exhaust manifold would make a lot of sense. On my intake manifold there is also a pressed in plug on the front at the end of the tube with that supplies each of the intake runners. I was thinking of pulling it and adding a fitting there as well. While helpful, both of those "solutions" wouldn't address the more likely points of issue in my manifold which is where the line to the valve makes the three 90° turns (why didn't they just run it straight to the valve??) and the four small lines to the intake runners. If I end up pulling the intake I will add four removable threaded allen plugs, one under each of the intake runner lines.

Andrew

[Richard Craneum]

I thought about the same thing and came up with some concept ideas.

One was to place the EGR Discharge tube by a spacer on the TBI or the Throttle on MPI. But I was wondering about a reaction time lag.

Another was using the same holes since is metered to that amount but is in a better location to clean since it can be accessed from the side without removing the manifold. Just an override tube from the exhaust to the intake manifold.

Another was, using some extra tubing and make it "A La Fuel Injector" making fittings for each runner like it was before with the benefit that all can be removed and cleaned it as need it.




The tube coming from the exhaust manifold can be covered with a heat proof cloth like GM does.

[keithert]

Does the 8 valve have similiar issues with it's EGR system?

[Richard Craneum]

I read yes they do. But I am thinking if you keep your car properly maintained you can minimize the amount of soot from the exhaust, therefore, keeping the EGR passages cleaner for a longer time.

[libbybapa]

Ha ha, that's some very wishful thinking. While keeping the engine running well will reduce the buildup, my engine has been running flawlessly.

The same issues occur in the 8v, but the routing of the system is such that it is much easier to clean out.

[libbybapa]

On another note, after running the test where I pressed on the diaphragm of the EGR valve (and doing nothing else AT ALL to the engine) I have now lost the function of cylinder #3... The engine ran perfectly right up until running that test. I'm sure it's a fluke, but my best guess is that a piece of carbon crap got pushed into either the intake valve seat or the spark plug... here's hoping for the spark plug. Yipes... It's either that or a remarkable coincidence that something else happened AT THE EXACT SAME TIME.

[Richard Craneum]

Perhaps the EGR is partially open and the 3rd runner has a better flow of Exhaust Gases.