Exhaust Gas Recirculation: Service and Repair

EGR VALVE INSPECTION AND CLEANING

CAUTION: If EGR passages in the intake manifold indicate excessive build-up of carbon deposits, the passages should be cleaned. Care should be taken to ensure that all loose particles are completely removed to prevent them from clogging the EGR valve, or from being ingested into the engine. Do not use chemicals or solvents to clean the EGR valve or intake manifold passages since chemicals may cause damage to the system. Wear approved eye protection for this cleaning procedure, to avoid possible injury to the eyes.

Clean the EGR valve as follows:

1. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve-to-manifold retaining bolts, and the control valve.
2. Carefully plug the EGR ports into the intake manifold with a clean shop towel or other suitable cloth. This will prevent debris from falling into the intake port. NOTE: Be sure to remove the cloth from the EGR port before installing the valve. Use compressed air to remove small debris.
3. With a wire wheel, remove the exhaust deposits from the mounting surface of the EGR valve and around the valve.
4. Look for exhaust deposits in the valve outlet, remove deposits as needed.
5. Clean intake manifold mounting surface.
6. Install valve assembly using new gasket, and reconnect the vacuum hose.



EGR INTAKE PASSAGE CLEANING


When cleaning the intake manifold EGR passages, care should be taken to ensure that all loose particles are completely removed to prevent them from clogging the EGR valve, or from being ingested into the engine.

1. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve-to-manifold retaining bolts, and the control valve (if applicable).
2. Remove the carbon deposits from EGR ports by hand using a suitable sharp tool.
3. Using compressed air, blow the EGR ports clean. Solvents should not be used to clean EGR valve or passages, since damage to the system may result.
4. Install EGR valve, using a new gasket, and reconnect the vacuum hose.



EVAPORTIVE CANISTER FILTER REPLACEMENT

Check the filter at the bottom of the vapor canister. If the filter is dirty, plugged, or damaged follow the proceeding instructions:

1. Remove all hoses from the top of the canister and mark, then remove the canister.
2. Remove the filter element by squeezing it out from under the lip surface at bottom of canister, and from under the retainer bar, where used.
3. Squeeze the new element under retainer bar, where used, and position it evenly around the entire bottom of the canister. Tuck the edges under the lip of canister.
4. Reinstall the canister to its original position on the vehicle.
5. Reconnect the hoses to the top of the canister, according to the labeling on top of canister. See VACUUM AND VAPOR HOSE DIAGRAMS for proper hose routing.



MAINTENANCE SCHEDULES

First 6,000 miles (10,000 km)

Throttle Body Bolt Mount Torque (see MECHANICAL SPECIFICATIONS) Check


Every 30,000 miles (50,000 km)

Fuel Tank, Cap & Lines Inspect
PCV Valve Inspect
Spark Plugs Replace
Spark Plug Wires Inspect

Every 30,000 miles (50,000 km) or 24 months

Engine Accessory Drive Belt(s) Inspect
Cooling System Service/Inspect

Every 30,000 miles (50,000 km) or 36 months

EGR System Inspect
Engine Air & PCV Filters Replace