excuse my french but this system is stupid, checked the egr its clear, and all the hoses are clean, switch works, colant temp sensor checks out, modulator works.  im outa options why is this not working and why does that EGR code keep coming up... please help i dont wana spend 500 to fix it.  its a 94 4 door 1.6 16v.  HELP A BROTHA OUT
S.Sidekick

Did you pull the EGR valve and clean out the port in the intake manifold? That has a tendency to get plugged up bad on city driven Track/Kicks.
Kelly

Did you pull the EGR valve and clean out the port in the intake manifold? That has a tendency to get plugged up bad on city driven Track/Kicks.
Kelly

Yep I did everything you did, but it still tossed the code.  So I took it back off got a coat hanger and cleaned out that port as much as I could.  Also sprayed alot of carb cleaner in there to get it out.... of course it didnt want to start after that, but soon it did.. and no code. 

You might need to pull the exhaust manifold to clean it out from that side.

yea i used a coat hanger still flashn that code.  please help...

I"m in the same boat, cleaned all that stuff out and can't get the code to go off for the life of me. The longest I've went after cleaning it is 50 miles before it comes back on. Very annoying.

any more ideas i dont notice it other than the gas mileage running 30" tires with cold air intake, full header preformance exhaust, new  iridium plugs and new rotor, i should be getting more than 25 miles to the gallon shifting at 3000rpms right?

I thought the 94 didn't have all the EGR garbage the 96 and up's have on them. 

I thought the 94 didn't have all the EGR garbage the 96 and up's have on them. 

yea, the 16v started in '93 (on 4drs) and it's EGR will clog ...
funnay is I have 2 rigs with an 8v and they have never been a prob, but the '93 16v I suspect is almost clogged (but not throwing code yet).

On mine, the tube between the EGR and the head plugged with carbon.  In addition to cleaning out the port on the head, I had to take the tube off and run a wire through it to clear out about an inch long blockage near the head end.

Hey,

Sorry to bring back the old EGR horror story, but after reading this and pretty much ever other post on the subject, I can get to the bottom of my EGR problem, code 51.

I have a 95, 16 valve, with an EGR system that runs through the inside much like the 96's but without the external tube.  I have removed my exhaust manifold, cleaned the tub there as far as I could.  I hit metal at the end meaning it must curve up or down.  Then removed, cleaned the EGR and the two addition holes through the intake manifold, both curve at the ends.  New solenoid.  Now when I run the engine, when I press on the EGR valve, it should stall the engine, but doesn't, which tells me there must be blockage somewhere.  The question is, whether there is another hole I can use to access and clean?  I read something about an EGR port behind a throttle plate?  Is that on the 95's 16 valve engines as well?

Any suggestions would be greatly appreciated,
C

any more ideas i dont notice it other than the gas mileage running 30" tires with cold air intake, full header preformance exhaust, new  iridium plugs and new rotor, i should be getting more than 25 miles to the gallon shifting at 3000rpms right?

The Kick should only get about 25 mpg.  I couldn't find the sight I wanted, but this will do:
http://www.fueleconomy.gov/feg/noframes/7399.shtml

Now when I run the engine, when I press on the EGR valve, it should stall the engine, but doesn't, which tells me there must be blockage somewhere. 

The "pull on the egr valve" should stall your engine out when cold, regardless of if you tubes are full of carbon.  The part that clogs up is your control system to open and close the EGR, not the EGR itself.  It sounds like you might actually have a bad valve.

With 29ish tires and a cat-back 2" on my 96 I get between 24 and 27mpg.  Not bad considering I still drive it like a toy. 

best I can get is around 21-22.