Cleaning EGR

[obradleyo]

I know the EGR is a hot topic with trac/kick's. So I think this will be a helpful topic.....I have been haveing some ideling issuses.. So on my days off this week I plan on fixing the idel issue...... My main questions does anyone know any good trick/tips for cleaning the EGR...... any help would be great....

[kick-fix]

clean hole #1
then do the stall test.

is your , CEL throwing Code 51?

EGR-problems?

hole 1

http://www.kick-fix.com/sensors/EGR/...-Perfecto1.jpg

of you dont have right of manifold top plenum SST tube the you have the EGR nozzle x4 manifold, a hard nut to crack.

[obradleyo]

no its not throwing any codes... just weird idle high idel on cold start races to 2k for a while over 60 sec. hot restart races to 2000 the drops to 800. In traffic stopped with a/c on surges between 1500 and 2000 turn off a/c and drops to 800.... so on my days off i plan on looking for vacume leaks , calibrate tps and clean egr... any thing else i should look at while im in there

[kick-fix]

check tps and for air leaks, pinch hoses and scratch head.

tell what you found , and we can help.

when you cold start an 16v its rich, and any air leaks at all will make her race.

[obradleyo]

where are the usaual spots that it leaks?
I havent been able to find anything yet

I have been fiddiling a small amount for the past few weeks

Where dose the cruse control hook into the vacum system? I have a feeling thats where its leeking at.
when I oraganly bought it there was cruse control but it didn't work. When I removed it a couple of weeks ago there wasn't any hoses tied to the system.... on the back of one of the CC peices there was a place to put a hose just no hose... So I'm hoping thats my problem...

[kick-fix]

Originally Posted by obradleyo

where are the usual spots that it leaks?
I havent been able to find anything yet.
95-16v, Major hard question, 16v has lots more due to 4 injectors and maf.
(best is to pinch hoses close to vac source to find leaks)
if all the tubing and (objects at end dont leak) is leak free and rpm dont drop when you pinch them you must look for level 2 leaks.

1: geedunk hose leaks. easy to find. as are the slaves at the end.
2: level 2 Injector cushions.
3: any leaks in front (towards the T are bad news.
4: all manifold gaskets level 3 leaks.

others< ISC base gasket leaks, TB gaskets leaks.
EGR base gasket leaks.

as they say , nature abhors a vacuum. is really accurate on 16v.
finding them all can be a hard job.
start easy stuff work to hard. best practice.

any leaks upstream of the MAF (it cant see it) is going to make a liar out of the maf, so the MAF lies to the ECU the ecu tries to correct with the O2 sensor and this may work with small leak. BUT not always and not at low rpms.



I have been fiddling a small amount for the past few weeks
FACTORY CRUISE?
Where dose the cruse control hook into the vacum system? I have a feeling thats where its leeking at. ( I dont think it does?)
cruise control module is electric 100% i think so it the motor that pulls throttle. ( you are thinking of Fords)


when I originally bought it there was cruse control but it didn't work. When I removed it a couple of weeks ago there wasn't any hoses tied to the system.... on the back of one of the CC pieces there was a place to put a hose just no hose... So I'm hoping thats my problem...

sounds non factory ,non OEM suzuki.

i will look it up.. when you pulled the cruise did you read the labels and
get the manufactures name plate and pn?
lots of after market stuff out there.




other bad leaks.
ISC air input hose must not leak. no cracks.

ah the EGR main valve on the back of motor must not leak Exhaust
when closed and must not be cracked and the main shaft bushing on it,
must not be so worn that it allows air to be sucked in.

vacuum is our friend and enemy.

i should make a list of every single leak.
i think they are random, we get a diff one here ever week.

[kick-fix]

try to think of that engine as a big air pump.
look at that induction manifold and plenum camber on top.
look at it and see all the stuff hanging off it.

all that stuff can leak.
be loose, be cracked ,or have bad gaskets.

if all the nipples on the manifod are used, and have no leaks.
then the issues with the cruise is a NON ISSUE.

forget the cruise and look at the induction.
see this, here are some places where air can suck in.
pinch all the hoses, no idle drop allowed, (isc tube you cant pinch or PCV)

pcv and isc air hose must be eye ball examined for perfection !
and clean PCV while at it.

the main TB to MAF.
there can be no leaks of air from those 2 points, NONE.


http://www.kick-fix.com/sensors/93-mpi-smog1.JPG



EGR;

clean hole #1 (always 1st , it always clogs , first and formost)
sounds bad but is 1000 time easier to clean then most cars and all kicks with the no man can go to , integreated intake runner EGR air nozzles.

then do the Stall test.

ask questions.

[kick-fix]

are you throwing code 51?

does the CEL lamp come on KEYON, no start and go out, after all types of running.

y/n

[kick-fix]

EGR.
first thing on any new car or a kick.

remove EGR and clean it to be spotless and so it snaps back hard and fast when cycled.
no carbon allowed on the seat.
no cracked diaphram.
no cracks in the casing. (hard to believe people ingore body cracks but they do)
no missing base gasket ,

then see if manifold port is clear with the egr removed, stuff a wire 12 inch into it and see if its clear.
on then put back EGR and clean hole 1 , even partial clogged is bad
then do the stall test.

all this is on the EGR page. (all is there)

[obradleyo]

hey jerry thanks a bunch I think I got it fixed.... so yesterday senice it wan't 100 out i got to work on the zuk all day.... I read on the fast idel subjuct for hours the past few days. So I frist started with the recent change to the air system I made. I recently changed back to the stock air box so I canged it back to my "hot air intake" cone air filter. that helped a little rpm at start up went from 2000 to 1800 on cold start. not sure if its cuz of the body lift or if the stock box leaks... will try going back to stock box sencie the idel issue is fixed

So the on to air leaks.. Did the picnch test no change in idle. looked the the hose connected to the PCV. there was a T on that connected to a long hose with a bolt in the end to plug it. So I pulled that off and put a new hose on and the rps dropped to 1500 at cold start...... Every thing else looked nice and tiddy with no leaks....new pvc also

Now to the egr After removing it all and atempting to clean it I rember Hey Ive done this before. when I rebuilt the head I cleane the entire egr system so that was all vary clean. so I put it all back to geather and did the quick test by pushing the diaphram. It bogged down and almost died. still at 1500 at start.

After all that I tried the set screw on top of the TB and that droped the rpm so 1200 and drops to 800 shortly after my only question is whin i turn the ac on the rpm goes up to 1500. Is that normal....