I've done the EGR manifold and engine port clean out twice! It's clean as a whistle now. I also removed the EGR valve and sprayed it clean, too. With all that, I'm still getting the EGR insufficient engine code. I suppose next up is to replace the EGR valve? There are some on ebay for abour $65. Any other suggestions?

 

At the base of the egr valve is a port that goes all the way to the intake manifold egr port. Did you check to make sure it isn't blocked? It's easy to check by blowing some air through it and see if it comes out the other end. Running a coat hanger in there with carb cleaner is the way to clean it out.

Also double check that you haven't installed the top intake manifold gasket (the small one) upside down. It will fit both ways, but the incorrect way will block the flow of gases and possibly give you this code. This is a common error on reinstall.

Other than that, check the service manual on how to test the EGR valve for proper operation before spending money on a new one. Search for the link to download the second gen service manual.

 

[quote=victus1;14141194]At the base of the egr valve is a port that goes all the way to the intake manifold egr port. Did you check to make sure it isn't blocked? It's easy to check by blowing some air through it and see if it comes out the other end. Running a coat hanger in there with carb cleaner is the way to clean it out.

yep. When I had the manifold off and the egr valve off, I sprayed cleaner in the port and watched it pool and exit out the egr valve base. I blew it out with compressed air. Did this several times. It's definately cleaned out. Manifold gasket is right, too. I'm at a loss, other than replacing the egr valve. I don't have a vacuum pump, so I can't test the one that's on there.

 

yep. When I had the manifold off and the egr valve off, I sprayed cleaner in the port and watched it pool and exit out the egr valve base. I blew it out with compressed air. Did this several times. It's definately cleaned out. Manifold gasket is right, too. It looked to be in good shape and no need to replace. I'm at a loss, other than replacing the egr valve. I don't have a vacuum pump, so I can't test the one that's on there.

 

I can only trust what you say about that gasket being the right side up. Like I said, it's easy to put it on the wrong way because it looks and fits fine either way.

If the gasket is ok, then I say test that egr valve. Download the service manual and follow the test procedure. I don't think you need a vacuum pump to test it...but you can always rent one from an auto parts store.

 

Make sure that you reset the CEL after any repairs.
The EGR valve very seldom goes bad, recheck your work and make sure everything is tight.

 

did you really clean the passage and each port with a wire hanger and carb cleaner--
thats what it takes to get the stuck crud out
just spraying a little fluid and calling it good is not enough
many use 3 cans of carb cleaner and a wire coat hanger to get it out

99s have 1, all later years have 6 egr ports- at the cylinder,
and there are bottem ports on the lower-block side of intake too

All must be clean or you get a low flow code

rare= would be the description of egr valve failure
it opens or it doesnt-- thats it
the rest is actual flow

note: the real techs tool for egr passage cleaning is a long flex rod- various diameters example 4- 6- 8- 10 mm, each with a barbed wire looking and metal brush surface
You soften the crud then go at it with these scrapers!

 

yeah, honest. I promise. I really, really, really cleaned that port out. Used a couple cans of spray and watched it pool and come out at the egr valve base. If it was still clogged, I doubt it would flow out so freely.

 

Assuming you have a 00-03, did you clean the egr tracks out of the top lid and the 6 holes in the intake manifold as well? And double check that that gasket is on correctly. It does fit both ways and if not on the right way it will cause that. Also did you reset the ecu after cleaning to make sure its fixed?

If all that is correct its possible the egr is bad.

 

Okay, so I removed the EGR valve again. Using a hex, I turned the plunger at the base a few times. I then used needle nose to retract the plunger and sprayed down in the hole until it started coming out the other hole. I let it soak a bit, then poured it out into the yard. I think applied voltage to #4 and #6 pins to actuate the plunger. It was going in and out so that's good. I buttoned everything back up and 40 miles later, no engine light. So far, so good.

I'm thinking that using the hex to twist the rod and spraying down in there might have done the trick. Maybe it needed that for extra cleaning. We shall see.

 

And this is a 99 3.2TL. Also found me a complete pdf service manual online.

 

Ahhh yes. The procedure for cleaning out the EGR valve is to open the plunger and spray carb cleaner in there. I used a flathead screwdriver to open it. When I cleaned mine lots of carbonized gunk came out of that plunger hole. And I let it soak for over an hour and flushed it out several times.

 

I'm back to say that you were right and I was wrong. I thought after cleaning the EGR valve that the code was gone. Nope. It came back. I decided to try one last time. Picked up some long steel bottle cleaning type brushes at Harbor Freight and removed the manifold a third time. I inserted the brush and twisted. Out came hardened deposits. It was jammed in there at the bottom. I kept twisting and spraying until I made it all the way through. Just to be sure I brought the manifold into the house and went inside a dark closet. I shined a flashlight into the hole and saw bare aluminum on the other side. I knew it was clean then. Buttoned it all back and NO MORE FREAKIN CODE.

I knew I did something right because after I buttoned it all back up I removed the EGR valve and the engine started surging. Never did that before when the valve was off. Success!

 

Glad to hear you finally fixed this. I was wondering what else could be causing your problem. There is a reason why 01tl4tl stresses that you must thoroughly clean the egr ports with brushes or coat hangers and lots of carb cleaner.