How do I clean the EGR valve?>>>

[auxmike]

I have the EGR with the black stack and the wired connector.I got an annoying chuggle/bottoming out at about 2500-2800 rpm under light throttle at times.VERY annoying.Never sets off SES though.I've put in new Saturn Genuine plugs and wires+Fuel filter,still has the problem after.
Can carbon be built up in there after 55k?
How do I clean this thing and the orifice it goes into?
If this don't do it,next stop TPS!

[Heartbeat - '95 SL2]

use the 'search' function here, and you'll find plenty of descriptions. Generally, it's "use carb cleaner and a stiff brush" and "clean the mounting hole too." Chilton guide says to use piano wire to clean the mounting hole, but I can't even picture that. Good luck, if it works, you save about $100 on the cost of a new EGR.

[auxmike]

Are these electronic EGRs prone to fail?You make it sound like the best fix is to replace it,is this true,or can these valves be cleaned periodicly?

[wolfman]

The linear electronic EGR valve used on 95' and above Saturns uses an electric "step motor" to open and close the EGR valve's pintle more precisely than the old vacuum operated valve. The LOWER portion of the valve has a visable shaft which can be cleaned if gummed up with deposits. The engine passage itself can be also. For the valve, CAREFUL application of a spray carb cleaner and an old toothbrush. Same goes for the engine passages, although a brass brush can be used to clean the engine aluminum.

[auxmike]

Wolf,can I vacuum out any loose carbon dust from the manifold after I scratch it off?
Also,does this sound like my problem,stumble on light accel at 2500-2800 RPM?

[wolfman]

Vacuum not really necessary but feel free. A stumble at 25-2800 rpm "could" very well be EGR related as that is the rpm range where maximum EGR function comes into play. General tune up items (plugs/wires/fuel injector cleaning) are also things to investigate.

[auxmike]

I did the plugs/wires/Fuel filter thing already.All genuine saturn goods too.
If the EGR is the culprit great,if not,TPS,here I come!
I also have the brown coolant temp sensor in my saturn parts goodie bag,just in case

[Luke]

Fm Wolf:

A stumble at 25-2800 rpm "could" very well be EGR related as that is the rpm range where maximum EGR function comes into play

With my cruise type of driving (slow), I found that my EGR became active at the 2000 mark, (( not to challenge Wolf)) and when I would have slight rpm stumbling at that rpm, within five seconds, the SES light would come on, setting a 32 code. This indicated that, in most cases, the unit needed to be cleaned. But I always had a code 32 set when this happened.

[auxmike]

I NEVER get a light!Is'nt that weird???

[sps SOHC]

my car was doing the exact same thing as you. I thought it was the spark plugs and when I slapped on the BOSCH, the only diff. I felt from them was NO MORE CHUGGING!

[auxmike]

I'm led to believe a different brand of plugs won't produce any better results than the Dealer bought NGKs I just installed.
I'm going to focus on the EGR next....

[Luke]

Mike:

I NEVER get a light!Is'nt that weird???

Then I would say the the EGR has a very low probabiity of the source of the problem.

[auxmike]

I thought any disruption in normal operation would trigger a SES code/light.How can the problem sneak by daily with out triggering the light?
The light works when I put the car in start,so it's not burn out...

[Heartbeat - '95 SL2]

Just my 2 cents, when mine went out, I couldn't even keep the car running -- once it was in gear, it would stall. No SES light, just stalling.

[auxmike]

Jason,you have OBDII right?Do you have the Linear electronic EGR valve in yours?

[wolfman]

In answer to the question "how can the valve have a problem without the ses light coming on?" The PCM (OBD2) monitors the POSITON of the EGR valve's pintle in relation to where it "should be" based on the signal being sent to and FROM the EGR valve. The valve itself can be working just fine BUT if some crud is preventing the pintle from sealing OR enough crud has built up to prevent proper regulated flow when the valve operates, it CAN affect operation without the PCM "seeing" anything "wrong" with EGR function. Just as in the older (PRE 95') cars with the vacuum operated valves, the PCM could only "see" problems with the electrical circuit of the EGR. A bad EGR valve in those cars actually RARELY set an SES light.

[auxmike]

Thanks Wolf!I'm going to see what I can do with that valve.Do I need use new gasket and hardware after cleaning?

[Luke]

Be kind to me all......for I may bereally off on this, but here goes...

Jason,you have OBDII right?

As I have a '95 SL2, my car has an OBDI, not II & does have aa linear EGR. With this observation, the recommendations may be different.

[auxmike]

Hmmmmmmmm...How many EGR valves have you gone through?

[wolfman]

Auxmike,
Provided the EGR valve gasket comes off in relatively good shape, you CAN reuse it. Rip or gouge it enough to cause a leak BETWEEN the ports or to the outside air and you'll need a new gasket. ( times out of 10 the gasket CAN be reused)