Fixing my EGR problem...

[jongillis]

This info is great! I have a 97 with about 70K, and the CEL has been on for about 3 months. AutoZone reported P0400 also (ERG Flow Malfunction), finally broke down and took to local Ford dealer, (Mazda dealer too far away) and had them put in new EGR valve. (part $352, test $139, labor $150) $641 total, that was this last Saturday the 4th of June. This morning I get the CEL light again. ($#@*&(&^'s). I plan on looking into the throttle body ports to clean but I don't seem to be able to get to the pics you posted of where they are located. Would it be possible to send them to me @ jongillis@sbcglobal.net. I would be most greatful.
Thanks,
Jon

[danbui]

Great job by 9milly7 in posting how to clean the EGR ports. My 1995 Millenia 2.5L engine with 140K miles had the same problem. The right port was totally closed with carbon deposit. The left port just has a small <1/8" hole remaining. I took both the input throttle and EGR valve as described and clean them with a scapper and carburator cleaner. I'm pretty sure the blocked EGR ports were the main cause of the followings:
1. OBD code P0400 (EGR system flow)
2. OBD code P1195 (Baro/EGR boost sensor)
3. High Nitrous oxide emission, almost failing California smog inspection

I have all three of these problems. I would have saved $500 in replacing the EGR/Barometric sensor if I had known about cleaning the EGR ports. Replacing the old EGR/Barometric sensor with a newer, more sensitive sensor did remove the P0400 and P1195 codes and did make the check-engine light dissappear. However it did not help in reducing the nitrous oxide emission.

I want to add the following notes to help others to clean the EGR ports and the EGR valve more easily:

I) To remove the input throttle easily, do:
1. Remove the battery.
2. Remove the air cleaner top assembly and the fitting/hose/pipe from the air cleaner assembly to the input throttle.
3. Remove the electrical connectors and gas pedal cable around the input throttle to get access.
4. The hose connected to the bottom rear of the input throttle does not need to be removed before removing the throttle. This hose is hard to remove. Just pull the input throttle out to the front with enough force to take the throttle out of the top two mounting screws.

The EGR valve does not need to be cleaned. My 140K miles EGR valve looks reasonably dry and clean. However, you can remove the EGR valve to check that the air can flow from the EGR ports to the EGR valve easily. You can use compressed air blower to check air passage by blowing into the EGR port. The air will be blown back to the opened mounting holding the EGR valve.

II) To remove the EGR valve easily, do:
1. Remove the electrical wire and mounting bracket on top of the EGR valve to get access.
2. Remove the vacuum hose on top of the EGR valve.
3. Remove the EGR valve mounting bolts.
4. Remove the EGR hose feeding into the EGR valve. This hose is dotted red.
5. Remove the water hose feeding into the EGR valve. This hose is not dotted red.

Now I'm very confident that my car will have low emissions . I had replaced the 2 pre-catalytic O2 sensors at 122K miles and noticed a significant reduction in carbon monoxide (CO) and hydrocarbon emissions (HC) (also noticed better fuel efficiency). I think a fully functioning EGR system will definitely reduces the nitrous oxide significantly.

[reality1011]

this is a good write up.... vote for sticky

[extermin8r]

thanks

[byronmars@gmail.com]

MY 1999 MILLENIA SPUTTERS ON THE ROAD AND IT HAS TROUBLE SHIFTING. IS THIS THE REASON?

[SteveSter]

Usually with a EGR problem the car wont idle right. An open egr wont affect the engine at higher rpms.

[mrwright2323@gmail.com]

I'm having trouble getting the Throttle body to open i can get it open for about 3 inches but it will not pull further. i've took out the four screws and the screw pointing down into the trottle body but it still seems like something else is holding it for the trottle to fully open... am i missing a screw or something??

[Saint_]

I'm having trouble getting the Throttle body to open i can get it open for about 3 inches but it will not pull further. i've took out the four screws and the screw pointing down into the trottle body but it still seems like something else is holding it for the trottle to fully open... am i missing a screw or something??[/b]

Is that an 2.5?

[mrwright2323@gmail.com]

yes....

[nnaylor@vt.edu]

Question...is there a gasket between the air intake and the throttle body (the parts you opened up to get to the egr ports), or are the surfaces just metal and bolted together? I'd like to know prior to opening this thing up. I've got a 2002 w/65k miles, 2.5L with the CEL giving me a PO400 as well as failure readings on both o2 sensors. I'm hoping the fix is as easy as this.