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ZUKIWORLD Discussion Forum => Technical Discussion - Beginner / Repair => Topic started by: Zuki-Girl on May 24, 2011, 06:48:33 PM

Title: EGR Problem
Post by: Zuki-Girl on May 24, 2011, 06:48:33 PM

Since I replaced the engine last February I've had a constant problem. The plug on the EGR valve keeps blowing out. I've had 4 aftermarket ones (Advance Auto,Autozone) and three from the local u-pull yard. I have no trouble codes showing,even driving and plug blows out. it's a 95 1.6 16 valve Kicker 4dr 5spd,2 wheel drive. My Sammi with it's 1.6 8 valve TBI conversion has no problem with it's EGR valve at all,and over twice the milelage. Any Ideas?

Title: Re: EGR Problem
Post by: rascott on May 24, 2011, 09:35:09 PM

this is real weird.
you mean the plug on the "back" opposite the diaphram?
i can't see how exhaust pressure could blow the thing apart.
does the kick run ok? mabe some detonation in the exhaust manifold?

Title: Re: EGR Problem
Post by: Zuki-Girl on May 25, 2011, 01:49:57 AM

I know it has me baffled too.

Title: Re: EGR Problem
Post by: Capt on May 25, 2011, 06:31:26 AM

Does your engine "Diesel" or "Run On" after you turn the key off?

The reverse intake pressure will also pop vacuum lines off.

CAPT

Title: Re: EGR Problem
Post by: Zuki-Girl on May 25, 2011, 01:18:08 PM

Nope it runs like a charm,no backfire or anything.

Title: Re: EGR Problem
Post by: Foot on May 25, 2011, 07:01:16 PM

Sounds like you may have a blocked port under the egr port in the intake. could you try removing the egr and poking around in there with a piece of wire to make sure it's open. My .02

Title: Re: EGR Problem
Post by: Zuki-Girl on May 26, 2011, 12:44:56 AM

With a long weekend coming up, I was thinking of pulling the EGR and checking there,also the steel tube. Neither of the two parts stores in the area have an EGR valve. So I'm going to put a freeze plug in it,drill above it and put a shear pin there. It might stop the plug from blowing out again. I'll keep everyone informed.

Title: Re: EGR Problem
Post by: wildgoody on May 26, 2011, 08:05:17 AM

A girl that can figure out and engineer stuff  ;D
I give you a tech point for your ingenuity, good idea

Wild

Title: Re: EGR Problem
Post by: Zuki-Girl on May 26, 2011, 01:15:03 PM

Thank you Wild. You should see the Sammi, 1.6 8 valve TBI conversion with a stand alone factory system,and full digital gauges.

Title: Re: EGR Problem
Post by: wildgoody on May 26, 2011, 10:01:34 PM

Well, do post some pics of the ride, or if you have, post the link
so we can check out the handy work

Title: Re: EGR Problem
Post by: Jluck on May 29, 2011, 12:55:10 PM

Quote from: Zuki-Girl on May 26, 2011, 12:44:56 AM

With a long weekend coming up, I was thinking of pulling the EGR and checking there,also the steel tube. Neither of the two parts stores in the area have an EGR valve. So I'm going to put a freeze plug in it,drill above it and put a shear pin there. It might stop the plug from blowing out again. I'll keep everyone informed.

I think I'm in love.... :-*

really though. good luck and do keep us posted. :)

Title: Re: EGR Problem
Post by: Zuki-Girl on May 29, 2011, 03:50:25 PM

LOL It's back together,along with the shear pin, I also ran a bead of the twp part POR putty. Letting everything dry another day. We'll fire it up Monday and see what goes.

Title: Re: EGR Problem
Post by: Zuki-Girl on June 03, 2011, 07:41:21 PM

tried posting the pics of the mods in here,but they must be way too large. Sent them to wild so he has them. If anyone wants pics let me know and I'll send them. Haven't figured out how to make them small yet. Better with wrenches than comps.

Title: Re: EGR Problem
Post by: Zuki-Girl on June 03, 2011, 08:13:56 PM

Thanks wild for fixing these.