EGR Valve

[RickFowler]

I have 96 Sidekick JX 196,000. I keep getting a check engine light for the EGR Failure. The EGR has been replaced and the lines have been cleaned. I have cleaned and replaced vacuum lines. The light will come on about 250 miles after each reset.

[fixkick]

yes, most do this,,,its a royal pain all that.
the first test is the stall test.

either push diaprham by hand (hard to do back there, behind the intake #4 runner)
or vacuum hand pump it, and do the leak down test too same time (1 at time)
the rpm must drop to p0400 or stall. if not the exh. path is blocked, or the mono port is packed, all all are , this old.
assumes new egr opens with vacuum (sure it does)
are you needing to pass smog, CEL out, test?
P0400 is EGR failure.
can be lots of things but the tests are easy.
1 stall
2 bark1 (pull bark tube, it barks at idle) rubber tube from EGR main to MOD valve base, it must bark or its nipple clogged or below fails.
3 bark2 (pull egr main, then use a rubber cork (my fav) at the vacuum port exposed there, does it bark now? at adjacent hole there (head exh) ?
yes, good, no then the head tunnel is packed (my 96,every path possible packed, day one, same on my 97)
yes, good. we continue...
ok then the vacuum side must be packed up (main stall test fails), called the mono port side 96+ or quad port side before 96'

gen 3 car, uSA, they reduced the 4 ports to just 1 in 1996 and moved it way up top(vastly easier to clean) the the TB rear plenum area.
this path too, can fail at just one point or many. (sidewider EGR pipe on up)
http://www.fixkick.com/EGR-Gen3.html

on the vacuum side, of EGR main. (egr injection port it is)
the side winder tube can clog mid section of pipe (cools and turns to coke there)
The TB is mounted to a large plenum sonic box. the backside of which contains the mono injector EGR port.
then at the back side if intake, the rear of mono port, clogs next.
and last where they ALL clog the mono port
seen here.
keep in mind, the 1 stall test fails, so we are working just that 1 failure here, there are others, (mod side and electric)
this exh side is the most hard to cure. so im showing that first. and stall did fail.
the vacuum modulation no electrics can work at all if the main stall fails.... so is first.


that gen 3 pages covers this. this is bark test 1, tube bark, fat see that tube,? if it don't bark, the mod does dead.
start engine heare that bark, that putt putt ?
http://www.fixkick.com/EGR-Gen3.html

my first slide show (96/97/98 all same) shows the mono port
see it here. (rare exception is x90 car. early 96 , July builds) but sidekicks are like below. in USA. all are. (OBD2 upgrades this is )
?

http://www.fixkick.com/sensors/EGR/97-cl...age_1.html

[RickFowler]

yes, most do this,,,its a royal pain all that.
the first test is the stall test.

either push diaprham by hand (hard to do back there, behind the intake #4 runner)
or vacuum hand pump it, and do the leak down test too same time (1 at time)
the rpm must drop to 400 or stall. if not the exh. path is blocked, or the mono port is packed, all all are , this old.
assumes new egr opens with vacuum (sure it does)
are you needing to pass smog, CEL out, test?
P0400 is EGR failure.
can be lots of things but the tests are easy.
1 stall
2 bark1 (pull bark tube, it barks at idle) rubber tube from EGR main to MOD valve base, it must bark or its nipple clogged or below fails.
3 bark2 (pull egr main, then use a rubber cork (my fav) at the vacuum port exposed there, does it bark now? at adjacent hole there (head exh) ?
yes, good, no then the head tunnel is packed (my 96,every path possible packed, day one, same on my 97)
yes, good. we
ok then the vacuum side is packed, called the mono port.
gen 3 car, uSA,
http://www.fixkick.com/EGR-Gen3.html

on the vacuum side, of EGR main. (egr injection port it is)
the side winder tube can clog mid section of pipe (cools and turns to coke there)
then at the back side if intake, the rear of mono port, clogs next.
and last where they ALL clog the mono port
seen here.
keep in mind, stall test fails so we are working just that 1 failure here, there are others, (mod side and electric)
this exh side is the most hard to cure. so im showing that first. and stall did fail.


that gen 3 pages covers this. this is bark test 1, tube bark, fat see that tube,? if it dont bark, the mod does dead.
http://www.fixkick.com/EGR-Gen3.html

my first slide show (96/97/98 all same) shows the mono port
see it here. (rare exception is x90 car. early 96 , July builds) but sidekicks are like below. in USA. all are. (OBD2 upgrades this is )
?

http://www.fixkick.com/sensors/EGR/97-cl...age_1.html

[fixkick]

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