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Old 03-16-2017, 05:36 PM   #1 (permalink)
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Default EGR Hell

Hi to all. About a month ago I finished an overdue engine rebuild due to a cracked block. Long story short. 2 years before this I had the Code 51, removed the IM and cleaned the hell out of everything. But like 2 months before the rebuild it came back. I then cleaned the IM again (it was clogged again, the tiny runner holes) while doing the rebuild, but it came back 2 weeks after putting car back to the road. I took the IM apart again and found 1 runner clogged again.

Things done so far after the last IM clean: Checked and double checked EGR main diaphragm and passages, the bark passage from exhaust #4, EGR Mod, Thermoprobe resistance (all in specs). Need to check VSV and ECT voltage and ohms. What elese can I do?

JUst last night found a tiny tiny crack at the #4 exhaust runner (can send pics). But other than that I dont know what else to check. Car idles at 800rpm hot, and to my best knowdledge no air leaks.

Hope someone can shed some light. Ill keep looking, but I get tire of landing the same place whenever code returns after clearing it and inspecting the possible culprit.

Cheers!!

PS: I have read and read many of the past posts regarding code 51 and they have been my guide in my problem. I just want to know if someone comes up with another solution.
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Old 03-17-2017, 07:38 AM   #2 (permalink)
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Well today I checked volts and Ohms at ECT and results were: Hot engine ohms 271 and plug connected running engine volts 0.57. To the best of my knowdledge all is within specs.

VSV volts, engine idling, reads 13.57v and closes meaning you blow and air comes out thru top filter. If I run a hose from plenum VSV nipple all the way to main EGR car stalls or tries to proving that EGR moves and I get 19HG vacuum with a gauge from that same nipple. Ill keep testing.

Good day to all.
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Old 03-17-2017, 10:08 AM   #3 (permalink)
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During your rebuild, when you had the exhaust manifold off, did you clean the EGR passageway in the exhaust manifold? I never heard this term before "the bark passage from exhaust #4", could you expand on this?
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Old 03-17-2017, 10:48 AM   #4 (permalink)
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If the EGR passage in the manifold is clear, exhaust pulses will generate a barking sound..

... Philip
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Old 03-17-2017, 11:25 AM   #5 (permalink)
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Yes, it was all cleaned thoroughly. Head was sent to machine shop for a complete job, and I double checked it before installing and just yesterday. And yes the Bark name comes from the sound heard when exhaust is coming out that passage when EGR main is removed.
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Old 03-17-2017, 11:27 AM   #6 (permalink)
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Exactly aquanaut20.

Any ideas guys? I'll do compression tests and check for sparkplugs tip condition just to make sure Im not running rich and if yes look for possible reasons.

Cheers.
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Old 03-17-2017, 01:25 PM   #7 (permalink)
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Does the '94 EGR system use just one VSV near the front, or is there a 2nd one on the back on the intake, like my '96 has? In my case, the front one was bad (no resistance, no click with power), but testing the rear one was also part of troubleshooting.
Also, my manifold was cracked and sucking/pushing air, so that was contributing too. Have you checked to see if yours is cracked all the way through? A piece of hose held to your ear works well for this test.
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Old 03-17-2017, 05:44 PM   #8 (permalink)
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Hi Jeckler. Only one in front of the plenum facing forward.

You mean Intake or exhaust. I did find a tiny tiny crack at exhaust on runner #4. Could that be the problem? Will do more testing on it, but Im running out of options on this one.

Thanks!!
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Old 03-17-2017, 06:09 PM   #9 (permalink)
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Quote:
Originally Posted by lifesawrench View Post
Hi Jeckler. Only one in front of the plenum facing forward.

You mean Intake or exhaust. I did find a tiny tiny crack at exhaust on runner #4. Could that be the problem? Will do more testing on it, but Im running out of options on this one.

Thanks!!
Exhaust. Mine was cracked about halfway around #4, which is the one that feeds the EGR. Replacing the manifold was what finally made P0400 (51 in OBDI speak) go away.
Using the hose test, it was VERY obvious it was leaking. It can also wreak havoc with the oxygen sensor.
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Old 03-20-2017, 03:23 PM   #10 (permalink)
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Well more test were done this weekend and all checked: ECT ohms and volts, spec, VSV ohms and live check passed (it clicks with 12v applied), TPS top pin 5v key on or running. The one I still have my doubts is the EGR mod, cause I dont have a hand vacuum to test. Other than that I refuse to think a tiny crack in Exhaust runner #4 is the culprit, but Ill address it, to rule it out. BTW all spark plug tips were free of black carbon or oily deposits and MAF was cleaned today also, just in case. Am I missing something?

Javier
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