EGR Passage Cleaning

WARNING:
Safety goggles MUST be worn during this procedure. Safety glasses do not provide adequate protection.

1. Disconnect the EGR valve's hoses. Remove the EGR valve from the intake manifold.

2. Insert a shop towel into the inner intake manifold opening. Reach through the outer opening, pull the towel across, making sure that it covers the underside of the outer opening (Figure 30).





3. Use an "O-Ring" pick and carburetor spray cleaner to remove carbon deposits from the intake manifold under carburetor EGR ports (Figure 31).





4. Use an "O-Ring" pick and carburetor spray cleaner to clean the EGR to intake manifold ports and Sub-EGR ports (Figure 32).

Note:
It may be necessary to use a wire in addition to the "O-Ring" pick to clean the ports.





5. Remove carbon deposits from the EGR Valve passages using carburetor spray cleaner and pick (Figure 33).


6. Using a new EGR valve gasket from the emissions kit, reinstall the EGR Valve.

7. Scrape the old carburetor base gasket from both the carburetor and the intake manifold.





8. Use a shop vacuum to remove carbon residue from the intake manifold openings (Figure 34). Carefully remove the shop towel by pulling it through the outer hole. Again use the shop vacuum to remove any carbon or gasket material from the intake manifold openings.

9. Shake the carburetor and listen for the roll-over ball rattle. If no rattle is heard repair as necessary.

10. Reinstall the carburetor using the reverse order of the removal procedure. Use the new carburetor gasket from the service kit. Remove the locking clamp pliers from the coolant hose and check all vacuum hose routings and carburetor fastener torques.

11. Refill the cooling system and pressure test for leaks.