EGR Function Testing - Chrysler Cars — Dodge Shadow I (1986-1994)

Non-Turbo

Check vacuum hoses for correct routing. Warm engine to operating temperature. Some models with EGR delay timers must run for at least 1-2 minutes before EGR works.
While observing EGR valve stem, abruptly accelerate engine to 2000-3000 RPM. EGR valve stem should move at least 1/8". Repeat test to confirm operation.
Connect a hand-held vacuum pump to EGR valve. Idle engine and gradually apply at least 10 in. Hg. EGR valve stem and diaphragm should move smoothly and engine speed should drop at least 150 RPM. If engine speed does not drop, check for plugged EGR passage.

Turbo

Check vacuum hoses for correct routing. Ensure engine is at normal operating temperature. Connect a hand-held vacuum pump to EGR valve. With engine idling, slowly apply 2-3 in. Hg. Engine RPM should drop when vacuum is applied.
Disconnect vacuum pump from EGR valve. Connect vacuum pump to EGR vacuum supply hose. Start engine and increase engine speed to 2000 RPM. Vacuum gauge should read about 5 in. Hg. If test results are as specified, system is functioning correctly.

2.6L Sub-EGR Valve

Check vacuum hoses for correct routing. Disconnect Green-striped vacuum hose from carburetor. Connect a hand-held vacuum pump to hose. With engine at idle speed, manually open sub-EGR control valve. Apply 6 in. Hg to EGR valve. Engine should run rough or stall. Reconnect vacuum hoses.

Floor Jet Type

Testing of this system is not required. To check floor jet, turn engine off. Remove air cleaner assembly. Hold choke and throttle valves open. Using a flashlight, visually inspect floor jets through carburetor. If jet is plugged, remove, clean and reinstall. Floor jet is stainless steel and non-magnetic. Care should be taken so that jet will not fall into intake manifold ports during removal and installation.

1.8L & 2.0L (California)

Connect a vacuum "T" fitting into Green-stripped vacuum hose from EGR valve, and connect a hand-held vacuum pump to "T" fitting.
Start and operate engine at idle. With engine cold and coolant temperature at less than 68°F (20°C), snap throttle open to race engine. If no change in vacuum reading is observed, system is okay.
Operate engine until coolant temperature is greater than 158°F (70°C). Snap throttle open to race engine. If vacuum increases to 4 in. Hg or greater, system is okay.
Disconnect vacuum pump from vacuum "T" fitting, and connect it directly to EGR valve. Apply 8.5 in. Hg. Engine should die or idle becomes unstable. If EGR system does not function as described, perform individual component testing.

2.0L (Federal & Canada)

Inspect hose connections between intake manifold, EGR solenoid and transducer, and EGR valve. Replace hardened, cracked and damaged hoses.
Ensure engine coolant temperature is more than 170°F (77°C). Put transmission in Neutral. Allow engine to idle for approximately 70 seconds. Suddenly accelerate engine to approximately 2000 RPM, but not more than 3000 RPM. EGR valve stem should move when accelerating engine. Repeat test several times to confirm EGR valve stem movement.
If EGR valve stem moves, EGR control system if functioning properly, go to next step. If EGR valve stem does not move, verify EGR solenoid operation. See SOLENOIDS under MOTORS, RELAYS & SOLENOIDS. After verifying solenoid operation, go to next step.
With engine idling at operating temperature, slowly apply vacuum to EGR valve. When vacuum reaches approximately 3.5 in. Hg, engine idle will become rough or engine may stall. If engine idle does not become rough or engine does not stall, go to next step. If engine idle becomes rough or engine stalls, EGR system is functioning properly.
Turn engine off. Remove EGR valve from vehicle. Connect a hand-held vacuum pump to EGR valve. Apply 20 in. Hg to EGR valve. If vacuum is maintained, go to next step. If vacuum is not maintained, replace EGR valve.
Apply 1.6 in. Hg or less to EGR valve. Air should not pass through EGR passages. If air does not pass through EGR passages, go to next step. If air passes through EGR passages, replace EGR valve.
Apply 8.7 in. Hg or more to EGR valve. Air should pass through EGR passages. If air passes through EGR passages, go to next step. If air does not pass through EGR passages, replace EGR valve.
Remove EGR vacuum hose from intake manifold. Connect a vacuum gauge to intake manifold nipple. Start engine. Gradually raise engine speed and observe vacuum gauge. Vacuum signal should remain fairly constant. If vacuum signal remains fairly constant, EGR system is functioning properly. If vacuum signal is not fairly constant, inspect intake manifold inlet passage. Repair or replace components as necessary.

2.2L/2.5L TBI & 2.5L Flexible Fuel

Check vacuum hoses for correct routing. Warm engine to operating temperature. Some models with EGR delay timers must run for at least 1-2 minutes before EGR works.
While observing EGR valve stem, abruptly accelerate engine to 2000-3000 RPM. EGR valve stem should move at least 1/8". Repeat test to confirm operation.
Connect a hand-held vacuum pump to EGR valve. Idle engine and gradually apply at least 10 in. Hg. EGR valve stem and diaphragm should move smoothly and engine speed should drop at least 150 RPM. If engine speed does not drop, check for plugged EGR passage.

EGR System Operation Check

Warm engine to operating temperature. Check condition of all EGR system tubes, hoses and electrical connections.
Start engine. Snap throttle to 2000-2800 RPM and check for EGR valve stem movement. If EGR stem moves, proceed to EGR GAS FLOW TEST. If no stem movement occurs, see TESTS W/CODES - 3.0L article in the ENGINE PERFORMANCE section for further testing procedures.

EGR Gas Flow Test

Warm engine to operating temperature. Disconnect vacuum hose from diaphragm (upper nipple) on EGR valve and attach a hand-held vacuum pump. With engine running, apply 3-5 in Hg. to EGR valve. EGR valve stem should move, and engine should stumble or even stall.
If EGR valve stem moved but idle speed remained steady, EGR valve, EGR tube, intake manifold or exhaust manifold may be plugged with carbon. Remove and clean/replace necessary components.
If EGR valve stem did not move, reapply vacuum to diaphragm and observe vacuum gauge on vacuum pump. If vacuum leaks down, diaphragm is ruptured and EGR valve must be replaced. If vacuum holds and stem does not move, carefully attempt to clean valve. If cleaning does not free stem, replace EGR valve.

Note. DO NOT use drills or wires to clean passages for EGR control system. Calibration of precision orifices could be altered, resulting in unsatisfactory vehicle operation.

3.3L & 3.5L

1994

Start engine. Allow engine to idle for 2 minutes. Disconnect EGR solenoid electrical connector. Disconnect EGR solenoid vacuum supply hose. Connect a vacuum gauge to disconnected hose. If vacuum gauge reads less than 10 in. Hg, repair vacuum supply to EGR solenoid. If vacuum gauge reads more than 10 in. Hg, Go to next step.
Reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve. Connect a vacuum gauge to disconnected hose. While observing vacuum gauge, momentarily increase engine speed to more than 2000 RPM. If vacuum gauge does not read 5 in. Hg, replace EGR valve. If vacuum gauge reads 5 in. Hg, go to next step.
Remove vacuum gauge from disconnected hose. Connect a vacuum pump to EGR valve nipple. Start engine and let idle. Slowly apply vacuum to EGR valve while observing engine idle. If engine idles rough or stalls as vacuum is applied, go to step 5). If engine does not idle rough or stall as vacuum is applied, go to next step.
Remove EGR valve and inspect manifold and tube for restrictions. Repair as required. If no restrictions are found, replace EGR valve.
If engine idles rough or stalls when vacuum is applied to EGR valve in step 3), turn ignition off. At this time, the condition required to set trouble code is not present. EGR SYSTEM FAILURE trouble code occurs when Powertrain Control Module (PCM) performs a test of the EGR system and monitors the oxygen sensor signal for a change. Possible causes are: EGR valve not opening, EGR transfer tube blocked, EGR passages in manifold blocked, failed EGR valve, failed EGR solenoid or failed PCM. Go to next step.
Inspect hoses and connectors. Repair as required.

1995 3.3L

Inspect hose connections between intake manifold, EGR solenoid and transducer, and EGR valve. Replace hardened, cracked and damaged hoses.
Ensure engine coolant temperature is more than 170°F (77°C). Put transmission in Neutral. Allow engine to idle for approximately 70 seconds. Suddenly accelerate engine to approximately 2000 RPM, but not more than 3000 RPM. EGR valve stem should move when accelerating engine. Repeat test several times to confirm EGR valve stem movement. If EGR valve stem moves, EGR control system if functioning properly, go to next step. If EGR valve stem does not move, remove hose from EGR valve and apply more than 4" vacuum to EGR valve. If valve does not hold vacuum or does not move, replace EGR valve. If EGR valve holds vacuum and moves, go to next step.
Remove vacuum hose from EGR valve. Connect a hand-held vacuum pump to EGR valve. With engine idling at operating temperature, slowly apply vacuum to EGR valve. When vacuum reaches 2.0-3.5 in. Hg, engine idle will become rough or engine may stall. If engine idle does not become rough or engine does not stall, go to next step. If engine idle becomes rough or engine stalls, EGR system is functioning properly.
Remove EGR valve and EGR tube. Inspect EGR valve and EGR tube for plugged passages. Also check intake manifold inlet passage. Repair or replace components as necessary. If necessary to replace EGR valve or EGR solenoid/transducer assembly, EGR valve and EGR solenoid/transducer assembly must be replaced together because they are calibrated to match each other.

1995 3.5L

Inspect hose connections between intake manifold, EGR solenoid/transducer assembly, and EGR valve. Replace hardened, cracked and damaged hoses.
Disconnect vacuum supply hose from EGR transducer solenoid. Connect a vacuum "T" in EGR transducer solenoid vacuum supply hose. Connect a vacuum gauge to vacuum "T". Start engine. Vacuum gauge should indicate a minimum of 15 in. Hg vacuum. If vacuum is at least 15 in. Hg, verify EGR solenoid operation. See SOLENOIDS under MOTORS, RELAYS & SOLENOIDS. After verifying solenoid operation, go to next step. If vacuum is not at least 15 in. Hg, repair or replace vacuum hoses as necessary.
Disconnect vacuum hose and backpressure hose from EGR transducer. Disconnect EGR solenoid electrical connector. Plug EGR transducer output port. (Scheme 3) Apply 1-2 psi air pressure to EGR transducer backpressure port. Using a hand-held vacuum pump, apply a minimum of 12 in. Hg vacuum to EGR transducer vacuum supply port. (Scheme 3)
Vacuum should momentarily hold, then slowly bleed off. If vacuum momentarily holds, then slowly bleeds off, go to next step. If vacuum does not momentarily hold, then slowly bleed off, replace EGR valve and EGR solenoid/transducer assembly. EGR valve and EGR solenoid/transducer assembly must be replaced together because they are calibrated to match each other.
Remove EGR valve from engine. Using a hand-held vacuum pump, apply 15 in. Hg to EGR valve. Check for EGR valve stem movement. If EGR valve stem moves, go to next step. If EGR valve stem does not move, replace EGR valve and EGR solenoid/transducer assembly. EGR valve and EGR solenoid/transducer assembly must be replaced together because they are calibrated to match each other.
If EGR valve stem moves approximately 1/8" (3 mm), maintain vacuum to EGR valve. EGR valve stem should remain open for approximately 30 seconds or more. If EGR valve stem remains open as specified, go to next step. If EGR valve leaks vacuum sooner, replace EGR valve and EGR solenoid/transducer assembly. EGR valve and EGR solenoid/transducer assembly must be replaced together because they are calibrated to match each other.
At this time all components are functioning properly. If EGR system is still not functioning properly, inspect port in rear of cylinder head for blockage and repair as necessary. Also check EGR backpressure tube for blockage and repair as necessary.

Scheme 3

1996

Inspect hose connections between intake manifold, EGR solenoid and transducer, and EGR valve. Replace hardened, cracked and damaged hoses.
Ensure engine coolant temperature is more than 150°F (66°C). Put transmission in Neutral. Allow engine to idle for approximately 70 seconds. Suddenly accelerate engine to approximately 2000 RPM, but not more than 3000 RPM. EGR valve stem should move when accelerating engine. Repeat test several times to confirm EGR valve stem movement. If EGR valve stem moves, EGR control system if functioning properly, go to next step. If EGR valve stem does not move, remove hose from EGR valve and apply more than 4" vacuum to EGR valve. If valve does not hold vacuum or does not move, replace EGR valve. If EGR valve holds vacuum and moves, go to next step.
Remove vacuum hose from EGR valve. Connect a hand-held vacuum pump to EGR valve. With engine idling at operating temperature, slowly apply vacuum to EGR valve. When vacuum reaches 2.0-3.5 in. Hg, engine idle will become rough or engine may stall. If engine idle does not become rough or engine does not stall, go to next step. If engine idle becomes rough or engine stalls, EGR system is functioning properly.
Remove EGR valve and EGR tube. Inspect EGR valve and EGR tube for plugged passages. Also check intake manifold inlet passage. Repair or replace components as necessary. If necessary to replace EGR valve or EGR solenoid/transducer assembly, EGR valve and EGR solenoid/transducer assembly must be replaced together because they are calibrated to match each other.

2.4L SFI & 2.5L MFI

For EGR function testing, see the following publications: ENGINE PERFORMANCE SERVICE & REPAIR manual.

1995

Inspect hose connections between intake manifold, EGR solenoid and transducer, and EGR valve. Replace hardened, cracked and damaged hoses.
Ensure engine coolant temperature is more than 170°F (77°C). Put transmission in Neutral. Allow engine to idle for approximately 70 seconds. Suddenly accelerate engine to approximately 2000 RPM, but not more than 3000 RPM. EGR valve stem should move when accelerating engine. Repeat test several times to confirm EGR valve stem movement.
If EGR valve stem moves, EGR control system if functioning properly, go to next step. If EGR valve stem does not move, verify EGR solenoid operation. See SOLENOIDS under MOTORS, RELAYS & SOLENOIDS. After verifying solenoid operation, go to next step.
With engine idling at operating temperature, slowly apply vacuum to EGR valve. When vacuum reaches approximately 3.5 in. Hg, engine idle will become rough or engine may stall. If engine idle does not become rough or engine does not stall, go to next step. If engine idle becomes rough or engine stalls, EGR system is functioning properly.
Turn engine off. Remove EGR valve from vehicle. Connect a hand-held vacuum pump to EGR valve. Apply 20 in. Hg to EGR valve. If vacuum is maintained, go to next step. If vacuum is not maintained, replace EGR valve.
Apply 1.6 in. Hg (DOHC) or 2.5 in. Hg (SOHC) or less to EGR valve. Air should not pass through EGR passages. If air does not pass through EGR passages, go to next step. If air passes through EGR passages, replace EGR valve.
Apply 8.7 in. Hg (DOHC) or 6 in. Hg (SOHC) or more to EGR valve. Air should pass through EGR passages. If air passes through EGR passages, go to next step. If air does not pass through EGR passages, replace EGR valve.
Remove EGR vacuum hose from intake manifold. Connect a vacuum gauge to intake manifold nipple. Start engine. Gradually raise engine speed and observe vacuum gauge. Vacuum signal should remain fairly constant. If vacuum signal remains fairly constant, EGR system is functioning properly. If vacuum signal is not fairly constant, inspect intake manifold inlet passage. Repair or replace components as necessary.

1996

Inspect hose connections between intake manifold, EGR solenoid and transducer, and EGR valve. Replace hardened, cracked and damaged hoses.
Ensure engine coolant temperature is more than 170°F (77°C). Put transmission in Neutral. Allow engine to idle for approximately 70 seconds. Suddenly accelerate engine to approximately 2000 RPM, but not more than 3000 RPM. EGR valve stem should move when accelerating engine. Repeat test several times to confirm EGR valve stem movement.
If EGR valve stem moves, EGR control system if functioning properly, go to next step. If EGR valve stem does not move, verify EGR solenoid operation. See SOLENOIDS under MOTORS, RELAYS & SOLENOIDS. After verifying solenoid operation, go to next step.
With engine idling at operating temperature, slowly apply vacuum to EGR valve. When vacuum reaches approximately 3.5 in. Hg, engine idle will become rough or engine may stall. If engine idle does not become rough or engine does not stall, go to next step. If engine idle becomes rough or engine stalls, EGR system is functioning properly.
Turn engine off. Remove EGR valve from vehicle. Connect a hand-held vacuum pump to EGR valve. Apply 20 in. Hg to EGR valve. If vacuum is maintained, go to next step. If vacuum is not maintained, replace EGR valve.
Apply 2.5 in. Hg or less to EGR valve. Air should not pass through EGR passages. If air does not pass through EGR passages, go to next step. If air passes through EGR passages, replace EGR valve.
Apply 6 in. Hg or more to EGR valve. Air should pass through EGR passages. If air passes through EGR passages, go to next step. If air does not pass through EGR passages, replace EGR valve.
Remove EGR vacuum hose from intake manifold. Connect a vacuum gauge to intake manifold nipple. Start engine. Gradually raise engine speed and observe vacuum gauge. Vacuum signal should remain fairly constant. If vacuum signal remains fairly constant, EGR system is functioning properly. If vacuum signal is not fairly constant, inspect intake manifold inlet passage. Repair or replace components as necessary.

Avenger, Sebring & Talon Non-Turbo

Inspect hose connections between intake manifold, EGR solenoid and transducer, and EGR valve. Replace hardened, cracked and damaged hoses.
Ensure engine coolant temperature is greater than 170°F (77°C). Place transmission in Neutral. Allow engine to idle for about 70 seconds. Quickly accelerate engine to about 2000 RPM, but not greater than 3000 RPM. EGR valve stem should move when accelerating engine. Repeat test several times to confirm EGR valve stem movement.
If EGR valve stem moves, EGR control system if functioning properly, go to next step. If EGR valve stem does not move, verify EGR solenoid operation. After verifying solenoid operation, go to next step.
Operate engine at idle and at operating temperature. Using a hand-held vacuum pump, slowly apply vacuum to EGR valve. When vacuum reaches about 3.5 in. Hg, engine idle will become rough or engine may stall. If engine idle does not become rough or engine does not stall, go to next step. If engine idle becomes rough or engine stalls, EGR system is functioning properly.
Turn engine off. Remove EGR valve from vehicle. Using a hand-held vacuum pump connected to EGR valve, apply 20 in. Hg to EGR valve. If vacuum is maintained, go to next step. If vacuum is not maintained, replace EGR valve.
Apply 1.6 in. Hg (DOHC) or 2.5 in. Hg (SOHC) or less to EGR valve. Air should not pass through EGR passages. If air does not pass through EGR passages, go to next step. If air passes through EGR passages, replace EGR valve.
Apply 8.7 in. Hg (DOHC) or 6 in. Hg (SOHC) or greater to EGR valve. Air should pass through EGR passages. If air passes through EGR passages, go to next step. If air does not pass through EGR passages, replace EGR valve.
Remove EGR vacuum hose from intake manifold. Connect vacuum gauge to intake manifold nipple. Start engine. Gradually increase engine speed and observe vacuum gauge. Vacuum signal should remain fairly constant. If vacuum signal remains fairly constant, EGR system is functioning properly. If vacuum signal is not fairly constant, inspect intake manifold inlet passage. Repair or replace components as necessary.

2.0L Turbo SFI

Disconnect vacuum hose with Green stripe from EGR solenoid located on firewall, just below wiper arm.
Using "T" fitting, install vacuum gauge between EGR solenoid and disconnected vacuum hose. Start engine and note vacuum with throttle at idle position and when quickly opening the throttle.
With engine coolant temperature of 68°F (20°C) or less, no vacuum should exist with throttle at idle and when quickly opened. With engine coolant temperature of 176°F (80°C) or more, no vacuum should exist with throttle at idle, but vacuum should momentarily increase to more than 3.9 in. Hg when throttle is opened quickly.
Shut engine off. Remove "T" fitting and vacuum gauge.
Start engine and allow engine to idle. Using vacuum pump, apply at least 7.9 in. Hg of vacuum at vacuum hose fitting on top of EGR valve while noting if engine stalls or engine idle becomes unstable. If engine stalls or engine idle becomes unstable, EGR valve is operating.
To check EGR valve vacuum supply, disconnect vacuum hose with White stripe from throttle body. This is the vacuum hose that goes from throttle body to EGR solenoid.
Connect vacuum gauge on throttle body where vacuum hose was connected. Start engine. Increase engine speed and note vacuum reading.
Vacuum should remain constant regardless of engine speed. If vacuum remains constant regardless of engine speed vacuum supply is okay. If no vacuum exists, check for restricted vacuum port on throttle body. Remove vacuum gauge and reinstall vacuum hose.

Except Talon Turbo

1997

Turn off all accessories. Start engine. Allow engine to warm to more than 170°F (77°C). Disconnect Exhaust Gas Recirculation (EGR) solenoid electrical connector. Leave EGR electrical connector disconnected for remainder of test.
Disconnect vacuum supply hose from EGR solenoid. Connect a vacuum gauge to disconnected hose. If vacuum gauge indicates more than 10 in. Hg vacuum, go to next step. If vacuum gauge indicates 10 in. Hg vacuum or less, repair vacuum supply to EGR solenoid.
Record vacuum reading. Reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve. Connect a vacuum gauge to disconnected hose. If vacuum gauge reading pulsates, go to next step. If vacuum gauge reading does not pulsate, go to step 6).
While observing vacuum gauge, momentarily raise engine speed to more than 2000 RPM. If vacuum gauge reading stabilized, go to next step. If vacuum gauge reading did not stabilize, replace EGR valve assembly.
Turn engine off. Remove EGR valve. Inspect manifold and tube for restrictions. If any restrictions were found, repair as necessary. If no restrictions were found, replace EGR valve assembly.
Reconnect hose to EGR valve. Disconnect backpressure hose from EGR transducer. Connect a pressure gauge to backpressure hose. If pressure gauge reading is not pulsating, go to next step. If pressure gauge reading is pulsating, replace EGR assembly.
Inspect exhaust system for a sizable leak. If no leaks were found, go to next step. If any leaks were found, repair exhaust system as necessary.
Inspect EGR valve mounting area, EGR valve tightness and EGR valve gasket. Repair or replace EGR valve as necessary. If no repairs were necessary, go to next step.
Replace EGR valve assembly.

1998

Turn off all accessories. Start engine. Allow engine to reach operating temperature. Disconnect Exhaust Gas Recirculation (EGR) solenoid electrical connector. Leave EGR solenoid electrical connector disconnected for remainder of test.
Disconnect vacuum supply hose from EGR solenoid. Connect a vacuum gauge to disconnected hose. If vacuum gauge indicates more than 10 in. Hg vacuum, go to next step. If vacuum gauge indicates 10 in. Hg vacuum or less, repair vacuum supply to EGR solenoid.
Reconnect vacuum hose to EGR solenoid. Disconnect vacuum hose from EGR valve. Connect a vacuum gauge to disconnected hose. If vacuum gauge reading pulsates, go to next step. If vacuum gauge reading does not pulsate, go to step 6) .
While observing vacuum gauge, momentarily raise engine speed to more than 2000 RPM. If vacuum gauge reading stabilized, go to next step. If vacuum gauge reading did not stabilize, replace EGR valve assembly.
Turn engine off. Remove EGR valve. Inspect manifold and tube for restrictions. If any restrictions were found, repair as necessary. If no restrictions were found, replace EGR valve assembly.
Reconnect hose to EGR valve. Disconnect backpressure hose from EGR transducer. Connect a pressure gauge to backpressure hose. If pressure gauge reading is not pulsating, go to next step. If pressure gauge reading is pulsating, replace EGR assembly.
Inspect exhaust system for a sizeable leak. If no leaks were found, go to next step. If any leaks were found, repair exhaust system as necessary.
Inspect EGR valve mounting area, EGR valve tightness and EGR valve gasket. Repair or replace EGR valve as necessary. If no repairs were necessary, replace EGR valve assembly.

1999

Turn ignition on with engine off. Using scan tool, read DTCs. If GLOBAL GOOD TRIP displayed is zero, go to step 3 . If GLOBAL GOOD TRIP is not zero, go to next step.
At this time the EGR system failure does not exist or is an intermittent problem. Using scan tool, read FREEZE FRAME data. Attempt to duplicate the condition that causes DTC to be set. While using FREEZE FRAME data, pay attention to the conditions such as vehicle speed, temperature, load and MAP sensor vacuum. If EGR system failure reoccurs, go to next step. If EGR system failure does not reoccur, misfire no longer is present.
Turn off all accessories. Start engine and allow to reach normal operating temperature. Disconnect EGR solenoid vacuum supply hose. Connect a vacuum gauge to disconnected hose. If vacuum is more than 10 in. Hg, go to next step. If vacuum is 10 in. Hg or less, repair vacuum supply to EGR solenoid.
Reconnect vacuum hose to EGR solenoid. Disconnect EGR valve vacuum hose. Connect a vacuum gauge to disconnected hose. If vacuum gauge pulsates, go to next step. If vacuum gauge does not pulsate, go to step 7 .
While observing vacuum gauge, momentarily raise engine speed to more than 2000 RPM. If vacuum gauge stabilized, go to next step. If vacuum gauge did not stabilize, replace EGR valve assembly.
Remove EGR valve and inspect manifold and tube for restrictions. If any restrictions are present, repair or replace manifold and tube as necessary. If restrictions are not present, replace EGR valve assembly.
Inspect exhaust system for a sizeable leak. If a leak was not found, go to next step. If a leak was found, repair as necessary.
Reconnect hose to EGR valve. Disconnect backpressure hose from transducer. Connect a pressure gauge to backpressure hose. If pressure gauge is not pulsating, go to next step. If pressure gauge is pulsating, replace EGR assembly.
Inspect EGR mounting. Check valve tightness and valve gasket. If any problems were identified, repair as necessary. If any problems were not identified, replace EGR valve assembly.

Talon Turbo