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Test TC-46A - EGR System Failure

NOTE: For connector terminal ID, see CONNECTOR IDENTIFICATION  Directory. For wiring diagram, see appropriate WIRING DIAGRAMS - NON-TURBO article.
  1. Turn off all accessories. Start engine. Allow engine to warm to more than 170°F (77°C). Disconnect Exhaust Gas Recirculation (EGR) solenoid electrical connector. Leave EGR electrical connector disconnected for remainder of test.
  2. Disconnect vacuum supply hose from EGR solenoid. Connect a vacuum gauge to disconnected hose. If vacuum gauge indicates more than 10 in. Hg vacuum, go to next step. If vacuum gauge indicates 10 in. Hg vacuum or less, repair vacuum supply to EGR solenoid. Perform TEST VER-2A.
  3. Record vacuum reading. Reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve. Connect a vacuum gauge to disconnected hose. If vacuum gauge reading pulsates, go to next step. If vacuum gauge reading does not pulsate, go to step 6).
  4. While observing vacuum gauge, momentarily raise engine speed to more than 2000 RPM. If vacuum gauge reading stabilized, go to next step. If vacuum gauge reading did not stabilize, replace EGR valve assembly. Perform TEST VER-2A.
  5. Turn engine off. Remove EGR valve. Inspect manifold and tube for restrictions. If any restrictions were found, repair as necessary. Perform TEST VER-2A. If no restrictions were found, replace EGR valve assembly. Perform TEST VER-2A.
  6. Reconnect hose to EGR valve. Disconnect backpressure hose from EGR transducer. Connect a pressure gauge to backpressure hose. If pressure gauge reading is not pulsating, go to next step. If pressure gauge reading is pulsating, replace EGR assembly.
  7. Inspect exhaust system for a sizable leak. If no leaks were found, go to next step. If any leaks were found, repair exhaust system as necessary. Perform TEST VER-2A.
  8. Inspect EGR valve mounting area, EGR valve tightness and EGR valve gasket. Repair or replace EGR valve as necessary. Perform TEST VER-2A. If no repairs were necessary, go to next step.
  9. Verify orientation of EGR transducer is horizontal. If EGR transducer is not horizontal, repair as necessary. Perform TEST VER-2A. If EGR transducer is horizontal, replace EGR valve assembly. Perform TEST VER-2A.
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