cleaning egr runners on 2.2
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Joined: Jan 2008
Posts: 78
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From: Minneapolis, MN
cleaning egr runners on 2.2
I just pulled dtc p0401, egr flow insufficient, so I knew it was finally time to clean the runners. So I figured that I might as well do a small right up.
Step 1
remove the gas cap to release the fuel pressure
Step 2
Disconnect the battery (make sure you have your anti-theft code for the radio if you still have the stock one)
Step 3
Remove the PCV valve and tuck it out of the way
Step 4
Disconnect the vacuum lines to the egr valve and the fuel pressure regulator
Step 5
Remove the 3 10mm nuts holding the fuel rail to the intake
Step 6
Carefully pull the fuel rail away from the intake, this will pull out all the injectors simultaneously. Its a good idea to keep a shop rag underneath in case some gas comes out with it.
Step 7
Prop up the fuel rail with a bungee cord or rope to keep it out of the way
Step 8
Remove the 5 10mm bolts holding the runner cover in place.
(at this point its a good idea to put a rag over the inlets of the injectors to keep out debris)
Step 9
Remove the cover
Step 10
The cover easily seperates in to its top and bottem. Open it. Clean out all the carbon build up with carb cleaner and a scrapper. Be gentle with the scraper, try not to score the surface which is aluminum and very soft. You need to remove all carbon build up so you dont have to see this thing for another 100k.
You cant tell from the above picture, but it is absolutely filthy.
After cleaning
Step 11
Now we move onto the ports going into the intake. 3 out of the 4 were completely plugged.
Use a piece of wire hanger to carve your way through the think build up.
some carb cleaner can be used to remove the remaining residue. don't shoot too much in though, just enough to clean out the remaining residue.
They should each look like this before you finish.
Step 12
Now reverse the procedure of disassembly. Use care when refitting the fuel rail and injectors. Make sure the injectors are all seated BEFORE you tighten the three nuts. Before starting, check all vacuum lines. Check the engine compartment for tools, rags etc. Clean up your area and put away your tools. Prime the fuel system by turning the key to the accessory position and check for fuel leaks around the injectors. If no leaks are present go ahead and start the car. The car will run very rough for about 30 seconds as it clears out the carb cleaner. You will notice a lot of smoke from the tail pipe. Once normal idle resumes, check again for fuel leaks around the injectors. If no leaks are present, then you are done.
Step 1
remove the gas cap to release the fuel pressure
Step 2
Disconnect the battery (make sure you have your anti-theft code for the radio if you still have the stock one)
Step 3
Remove the PCV valve and tuck it out of the way
Step 4
Disconnect the vacuum lines to the egr valve and the fuel pressure regulator
Step 5
Remove the 3 10mm nuts holding the fuel rail to the intake
Step 6
Carefully pull the fuel rail away from the intake, this will pull out all the injectors simultaneously. Its a good idea to keep a shop rag underneath in case some gas comes out with it.
Step 7
Prop up the fuel rail with a bungee cord or rope to keep it out of the way
Step 8
Remove the 5 10mm bolts holding the runner cover in place.
(at this point its a good idea to put a rag over the inlets of the injectors to keep out debris)
Step 9
Remove the cover
Step 10
The cover easily seperates in to its top and bottem. Open it. Clean out all the carbon build up with carb cleaner and a scrapper. Be gentle with the scraper, try not to score the surface which is aluminum and very soft. You need to remove all carbon build up so you dont have to see this thing for another 100k.
You cant tell from the above picture, but it is absolutely filthy.
After cleaning
Step 11
Now we move onto the ports going into the intake. 3 out of the 4 were completely plugged.
Use a piece of wire hanger to carve your way through the think build up.
some carb cleaner can be used to remove the remaining residue. don't shoot too much in though, just enough to clean out the remaining residue.
They should each look like this before you finish.
Step 12
Now reverse the procedure of disassembly. Use care when refitting the fuel rail and injectors. Make sure the injectors are all seated BEFORE you tighten the three nuts. Before starting, check all vacuum lines. Check the engine compartment for tools, rags etc. Clean up your area and put away your tools. Prime the fuel system by turning the key to the accessory position and check for fuel leaks around the injectors. If no leaks are present go ahead and start the car. The car will run very rough for about 30 seconds as it clears out the carb cleaner. You will notice a lot of smoke from the tail pipe. Once normal idle resumes, check again for fuel leaks around the injectors. If no leaks are present, then you are done.
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Joined: Oct 2013
Posts: 15
Likes: 1
From: Houston, TX
I did my EGR runners, here is how they came out:
Fuel Injectors
EGR Runners Before
EGR Runners After
Results: No Engine Light! Thanks for the write up! Gotta be careful with the Fuel Injectors Seals and make sure you don't drop them!
Fuel Injectors
EGR Runners Before
EGR Runners After
Results: No Engine Light! Thanks for the write up! Gotta be careful with the Fuel Injectors Seals and make sure you don't drop them!
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