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How to Clean Mechanical EGR Valve

Since the 1960s, vehicle manufacturers have installed Exhaust Gas Recirculation (EGR) valves to reduce nitrous oxide (NOX) emissions. The EGR valve recirculates a small amount of exhaust into the combustion cycle. The warmth of the exhaust lets the combustion chambers warm up quickly, while the spent, inert gases keep the chambers from getting too hot when the engine fully warms up. Whether mechanical or electronic, EGR valves open and close to control the gas flow. If left open, the excess vacuum will cause the engine to act like it wants to stall, idling roughly or surging. If the valve stays closed, detonation could occur in the combustion chambers; this knocking or pinging will lower mileage and the lifespan of the engine. To smooth a rough idle, or hesitant or surging acceleration, and reduce knocking, clean your EGR valve.





Clean and inspect the vacuum hose. Remove the vacuum hose and inspect closely for wear (cracks or weak spots), then clean out the carbon deposits either with a spray can of carburetor cleaner or with a pipe cleaner if the deposits are hardened or compacted.







Inspect the EGR valve for damage. 
Loosen any bolts fastening the EGR valve to the engine. Inspect the gasket lining the bottom plate of the valve. If it's not frayed or cracked, you can reuse it.


Clean the return tube and gas entry port. Use carburetor cleaner and a small-bristled brush like a wire brush, toothbrush or pipe cleaner to clean off the carbon from the metal exhaust gas return tube and the gas entry port on the valve (usually the smaller hole with a spring-loaded pin, or “pintle”).
If there is a lot of carbon build up around the EGR valve, you may also want to just save yourself some time and replace it with a new one.







Clean out the entry port. The entry port is where the valve tubes connect to the engine (usually the intake manifold) while the EGR valve is off.











Reinstall the EGR valve. 
Check to ensure the vacuum diaphragm moves freely, reinstall the EGR valve and reattach the exhaust return and vacuum hoses.









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