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Test TC-46A - EGR System Failure

  1. Ensure all accessories are off. Start engine and warm engine to normal operating temperature.
  2. Disconnect electrical connector from EGR solenoid. The EGR solenoid is located on top of EGR backpressure transducer which contains vacuum hose to EGR valve. See Fig 1.
    NOTE: Electrical connector from EGR solenoid should be disconnected for the remaining portion of this test. When this test is complete, use scan tool to clear Diagnostic Trouble Codes (DTCs) from Powertrain Control Module (PCM).
    Fig 1: Locating Typical EGR Solenoid & Components
    G98G00642
  3. Disconnect vacuum supply hose from EGR solenoid. See Fig 1. Using vacuum gauge, check vacuum on vacuum supply hose for EGR solenoid. If vacuum is more than 10 in. Hg, go to next step. If vacuum is 10 in. Hg or less, repair vacuum supply to EGR solenoid. Perform TEST VER-2A - ROAD TEST VERIFICATION .
  4. Reinstall vacuum supply hose on EGR solenoid. Disconnect vacuum hose from top of EGR valve. See Fig 1.
  5. Connect vacuum gauge on vacuum hose for EGR valve. If vacuum reading pulsates, go to next step. If vacuum reading does not pulsate, go to step  9.
  6. Monitor vacuum reading while momentarily increasing engine speed to more than 2000 RPM. If vacuum reading stabilizes, go to next step. If vacuum reading does not stabilize, replace EGR valve assembly. Perform TEST VER-2A - ROAD TEST VERIFICATION .
  7. Remove EGR valve. Inspect EGR valve, intake manifold and signal tube for restrictions. Signal tube is located below EGR valve. See Fig 1.
  8. If restrictions exist, repair or replace components as necessary. Perform TEST VER-2A - ROAD TEST VERIFICATION . If no restrictions exist, replace EGR valve assembly. Perform TEST VER-2A - ROAD TEST VERIFICATION .
  9. Reinstall vacuum hose on top of EGR valve. Disconnect backpressure hose from bottom of EGR backpressure transducer. See Fig 1.
  10. Install pressure gauge on backpressure hose. If pressure reading does not pulsate, go to next step. If pressure reading pulsates, replace EGR valve assembly. Perform TEST VER-2A - ROAD TEST VERIFICATION .
  11. Check for sizeable exhaust leaks. If sizeable exhaust leaks exist, repair as necessary. Perform TEST VER-2A - ROAD TEST VERIFICATION . If no sizeable exhaust leaks exist, check for loose EGR valve mounting bolts or defective EGR valve mounting gasket.
  12. If loose EGR valve mounting bolts or defective EGR valve mounting gasket exist, repair as necessary. Perform TEST VER-2A - ROAD TEST VERIFICATION . If EGR valve mounting bolts and EGR valve mounting gasket are okay, replace EGR valve assembly. Perform TEST VER-2A - ROAD TEST VERIFICATION .
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