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THE INTAKE PIPE BETWEEN THE INTERCOOLER AND THE INLET MANIFOLD KEEPS PRESSURISING AND PARTING WHEN CAR IS REVVED.WHY?, THE EGR BODY AND VALVE ,MANIFOLD AND LINK PIPE ARE CLEAN.
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The EGR valve is a device that reduces the emissions of the engine by recirculating some of the exhaust gas back into the intake manifold. The EGR valve is located in the engine compartment, near the firewall on the driver's side. It is attached to a metal pipe that connects to the exhaust manifold. To access the EGR valve, you will need to remove the air intake hose, the throttle body, and the EGR tube.
1.6)EGR - Exhaust Gas Recirculation valve(actuator) What is it? This is a device that reduces engine emissions of nitric oxides by allowing a measured amount of exhaust gas to re-enter the intake manifold and mix with the air prior to entering the cylinders.The EGR can be vacuum (older types) or electrically driven (modern) or a hybrid combination of both (intermediate age).Adding inert exhaust gas to the intake charge artificially enriches the fuel air mix (by diluting the air) and thereby reduces ignition temperatures associated with lean running conditions Where is it located?The EGR is associated with the intake manifold.The EGR is sited at a point of contact with both the exhaust and intake manifolds.If the exhaust manifold is remote to the inlet manifold, for example onthe other side of the engine, an exhaust feed pipe leading from the exhaustmanifold to the EGR is provided. How does it work?Generally intake manifold vacuum acting on a diaphragm draws up on a pintle valve to open a connection between a (usually round) entry port for the exhaust gases and an exit port (usually rectangular) to the intake manifold.The opening of some modern EGR valves iscompletely under the (ECU) control of an electrical motor/solenoid.Since an open EGR port effectively acts as a vacuum leak in the inlet manifold leading to potential starting and idling difficulties, the EGR valve operation is often impeded by an electrical over-ride at cold/start-up until the engine reaches running temperature and high revs. The ECU takes signals from the coolant temperature sensor to determine when the engine is hot before allowing the EGR to function.In some cases, a differential pressurefeedback exhaust (DPFE) sensor, connected to pipes on the exhaust feed to the EGR, informs the ECU when and by how much the EGR should be open. NEXT 1.6b) EGR faults and how to fix
Replace the valve cover gasket if the valve cover gaskets are
leaking or if they're worn. The procedure is as follows:-- 1)First of all let the motor cool down if the car was recently driven. Then remove the air
intake boot.The air intake boot ios attached to the engine's throttle body. 2)Carefully disconnect the throttle
cable , hoses and electrical connectors located on the upper intake manifold. 3)Then disconnect the hard pipe that is
connected to the EGR (exhaust gas recirculation) valve. 4)The EGR valve is located beneath the upper intake manifold. 5)Then remove the bolts from both the upper intake manifold and the manifold
support bracket. 6)Now the upper intake main fold and
lower intake manifold both have got loose as you removed the nut. 7)After that remove the upper intake
manifold from the lower intake manifold. Carefully place clean rags over the
intake runners to prevent anything from falling into the intake system. 8)Then you will have to disconnect the
crank case breather valve on the valve cover. 9)Then remove the bolts from the valve
cover and remove the reinforcing straps. 10)Then remove the camshaft belt cover
and the dust shield from the back of the camshaft sprocket. 11)Now carefully remove the valve cover.
Properly clean the old gasket material with gasket remover. 12)You can install a new gasket in the reverse procedure of removal.
Fig. 4: Exploded view of the EGR system and related components for the 4.0L engine (click over pic for zoom) REMOVAL & INSTALLATION
PFE/DPFE Sensor This component is found on all engines, and is also referred to as the backpressure transducer.
Disconnect the negative battery cable.
Detach and label the wiring harness connector from the PFE/DPFE sensor.
Disconnect all of the hoses from the sensor.
Remove the mounting nuts, then separate the sensor from the mounting bracket.
If necessary, remove the EVR solenoid and the PFE/DPFE mounting bracket from the upper intake manifold.
To install:
If removed, install the EVR solenoid and mounting bracket onto the upper intake manifold.
If applicable, install the EGR tube heat shield.
Position the PFE/DPFE sensor on the mounting bracket, then install and tighten the mounting nuts until snug.
Attach all necessary hoses and wiring to the sensor.
Connect the negative battery cable.
EGR Vacuum Regulator (EVR) Solenoid The EVR solenoid is mounted either on the same bracket as the
PFE/DPFE sensor, attached to the upper intake manifold, or near the EGR
valve on its own bracket.
Disconnect the negative battery cable.
Label and detach the wiring harness connector from the EVR solenoid.
Detach the main emission vacuum control connector from the solenoid.
Remove the retaining nuts, then separate the solenoid from the mounting bracket.
To install:
Position the solenoid on its mounting bracket and install the retaining nuts.
Attach the main emission vacuum control connector and the wiring harness connector to the EVR solenoid.
Connect the negative battery cable.
EGR Valve See Figures 6 and 7
Disconnect the negative battery cable.
If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
Label and detach all vacuum hoses from the EGR valve.
Label and detach any electrical wiring harness connectors from the EGR valve.
Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
Fig. 6: Cutaway view of a base entry type EGR valve
Fig. 7: Cutaway view of a side entry type EGR valve To install:
Install the EGR valve, along with a new gasket, on the upper
intake manifold, then install and tighten the mounting bolts to 4-22 ft.
lbs. (20-30 Nm) on 3.8L engines, or to 106-49 inch lbs. (1-18 Nm) on
5.0L engines.
Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
Connect all wiring or hoses to the EGR valve.
Install the air inlet tube.
Connect the negative battery cable.
Hope this helps, good luck (remember to rate this comments).
If the manifold was replaced, install or connect the following:
Vacuum source manifold.
Positive Crankcase Ventilation (PCV) valve.
Manifold Absolute Pressure (MAP) sensor.
Throttle body assembly.
Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold.
NOTE: Apply thread lock compound, to the bolt threads before assembly.
Install or connect the following:
Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
Accelerator and the cruise control cables with the bracket to the throttle body.
EVAP purge solenoid vacuum line to the throttle body.
Connect the electrical connectors to the following:
Mass Air Flow (MAF) sensor
Manifold Absolute Pressure (MAP) sensor
Idle Air Control (IAC) valve
Throttle Position (T/P) sensor
EVAP purge solenoid
Install or connect the following:
Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
Fig. 11: EGR valve and component mounting-3.0L engine
Fig. 12: EGR valve and component mounting-3.8L engine
Removal:
Disconnect the negative battery cable.
If necessary, remove the air inlet tube from the throttle body and air cleaner housing.
Label and detach all vacuum hoses from the EGR valve.
Label and detach any electrical wiring harness connectors from the EGR valve.
Disconnect the EGR valve-to-exhaust manifold tube from the EGR valve.
Remove the EGR valve mounting fasteners, then separate the valve from the upper intake manifold.
Remove and discard the old EGR valve gasket, and clean the gasket mating surfaces on the valve and the intake manifold.
To install:
Install the EGR valve, along with a new gasket, on the upper
intake manifold, then install and tighten the mounting bolts to 15-22
ft. lbs. (20-30 Nm) on 3.8L engines, or to 106-159 inch lbs. (12-18 Nm)
on 5.0L engines.
Connect the EGR valve-to-exhaust manifold tube to the valve, then tighten the tube nut to 30 ft. lbs. (41 Nm).
Connect all wiring or hoses to the EGR valve.
Install the air inlet tube.
Connect the negative battery cable.
Hope this helps (remember comment and rated this).
The EGR (exhaust gas recirculation) valve What is it? This is a device that reduces engine emissions
of nitric oxides by allowing a measured amount of exhaust gas to re-enter the
intake manifold and mix with the air prior to entering the cylinders.The EGR can be vacuum or electrically driven
or a combination of both. Where is it located?The EGR is most often associated with the intake manifold.The EGR will be sited at a point of contact
with both the exhaust and intake manifolds.If the exhaust manifold is remote, for example on the other side of the
engine to the intake manifold, there will often be an exhaust feed pipe leading
from the exhaust manifold to the EGR
sited on the intake manifold. How does it work?Generally intake manifold vacuum acting on a diaphragm draws up on a
valve to open a connection between an entry port from the exhaust gases and an
exit port to the intake manifold.An
open EGR port makes starting difficult so the valve operation is often impeded by
an electrical over-ride until the engine has warmed up, as signaled to the ECU
by the coolant temperature sender.In
some cases, a differential pressure
feedback exhaust (DPFE) sensor fed by pipes from the exhaust feed to the
EGR informs the ECU when and by how much the EGR should be open. Symptoms of faulty EGR The EGR has
two possible fault modes either it is a) open when it should be closed or b)
closed when it should be open. (some EGR faults are in fact more likely to be DPFE related)
Poor idling:‘hunts’ at idle
and generally rough engine performance.This is due to the air ingress through the split diaphragm or the
EGR valve being left open, either event compromises the intake manifold
vacuum and in turn this interferes with the ECU’s ability to deliver accurate
fuel to air ratio for a given engine speed.
Misfire and ‘pinking’:if the EGR is jammed closed or the
exhaust feed pipe is blocked (e.g. gummed up with baked carbon) the engine
ignition runs lean and very hot, so hot in fact that the fuel air mix can
spontaneously ignite causing a misfire.The misfire if pronounced can, in turn, be detected by the engine
knock sensors and this gives the appropriate on board diagnostic error
codes along with the check engine light.Due to the diesel engines creating more soot in the exhaust a blocked
EGR is a much more common complaint in diesels than petrol cars.
Surging:A sticking EGR valve can lead to an
effect of rhythmic surging a bit like the MAF fault, especially in turbo
charged engines.Normally on a
warmed up engine the vacuum from the inlet manifold opens the EGR.If the EGR fails to open promptly the
turbo can be subject to a slight boost.Extra fuel/air mix is pushed into the inlet manifold as a result,
increasing pressure (decreasing the vacuum).Without vacuum in the inlet manifold the
EGR closes again but if sticky does so only slowly.This may allow inlet gases to flow
through the EGR into the exhaust manifold for a split second.There is a time lag in the sequence of
these events leading the engine to surge in cyclical manner.
How to check?With the engine running it may be possible to force the EGR valve open
by pressing on the diaphragm with one’s fingers.Failing that pulling off the vacuum line to
the EGR, blocking the pipe on the inlet manifold and applying vacuum to the EGR
to monitor function will determine if the diaphragm is split.Removal of the EGR assembly and examination
of the ports and valve mechanism will reveal any carbon build up. How to fix? If the diaphragm is split then the
EGR needs to be replaced.Most EGR problems are linked to carbon
soot build up and this can be cleaned using a cloth, brush and carburetor choke
cleaner spray.If the exhaust feeder
pipe is blocked this can be cleaned using a piece of frayed hand brake cable as
an internal brush. This makeshift brush can be further enhanced by mounting it
in a drillto sweep dirt from the interior of lengths of pipe.Some cars (Hondas are a good example) have an
elaborate passage way system to provide exhaust gas to each inlet pipe runner.The only way to clean these out is by
removing the blanking plugs (no easy task) and then using the makeshift rotary wire
brush and carburetor choke spray.New
blanking plugs have to be reinstated to make good the passage ways assembly.
change your egr valve on the car and the problem should be rectified.
the egr valve exhaust gas recirculation valve send exhaust gase back to the inlet manifold to keep the air fuel fuel mixture at the right temp and the exhaust manifold from over pressurising.
if this fail seizes shut it stop the recirculation from happening yuo cant just clean them though they have to be replaced
Before servicing the vehicle, refer to the Precautions section.
Relieve the fuel system pressure.
Drain the cooling system.
Remove or disconnect the following:
Negative battery cable
Supercharger
Thermostat housing
Exhaust Gas Recirculation (EGR) tube at the intake manifold
Engine Control Temperature (ECT) sensor
Intake manifold
To install:
Install or connect the following:
Intake manifold with new gaskets. Torque the bolts, working from
the center out, to 11 ft. lbs. (15 Nm).
ECT sensor connector
EGR tube to the intake manifold
Thermostat housing
Supercharger
Negative battery cable
Refill and bleed the cooling system.
Run the engine and check for leaks and proper engine operation.
VIN K Engine
Before servicing the vehicle, refer to the Precautions section.
Disconnect the negative battery cable.
Drain the cooling system.
Relieve the fuel system pressure.
Remove or disconnect the following:
Fuel injector sight shield
Air inlet duct
Spark plug wires from the right side
Manifold Absolute Pressure (MAP) sensor
Vacuum lines from the intake manifold
Fuel lines
Fuel injector electrical connectors
Fuel regulator vacuum line
Fuel rail from the intake manifold
Exhaust Gas Recirculation (EGR) heat shield
Throttle cable bracket from the cylinder head mounting bracket and
the throttle body cables
Throttle body support bracket
Upper intake plenum and gasket
Thermostat housing
Electrical connector from the Engine Coolant Temperature (ECT)
sensor
Drive belt tensioner assembly
EGR valve outlet pipe
Lower intake manifold
Fig. Exploded view of the intake manifold and related
components-3.8L (VIN K) engine
Install or connect the following:
Intake manifold using new manifold gaskets. Torque the bolts in
sequence to 11 ft. lbs. (15 Nm); then, re-torque to 11 ft. lbs. (15 Nm).
EGR valve outlet pipe
Drive belt tensioner assembly. Torque the tensioner bolts to 37
ft. lbs. (50 Nm).
Electrical connector to the ECT sensor
Thermostat housing
Upper intake plenum. Torque the intake plenum bolts to 88 inch.
lbs. (10 Nm).
Throttle body support bracket
Throttle cable bracket to the cylinder head mounting bracket and
the cables to the throttle body lever
EGR heat shield
Fuel rail. Torque the fuel rail bolts to 88 inch. lbs. (10 Nm).
Fuel lines
Fuel regulator vacuum line
Fuel injector electrical connectors
Vacuum lines to the intake manifold
MAP sensor
Spark plug wires
Fuel injector sight shield and air inlet duct
Negative battery cable
Refill and bleed the cooling system.
Run the engine and check for leaks and proper engine operation.
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