EGR Function Testing - Ford - Imports Ford Festiva I

1974 Capri & All Courier Models (Ported EGR Valve)

1. Check vacuum lines for correct routing. Disconnect vacuum hose at EGR valve. Plug hose end. Connect a hand-held vacuum pump to EGR valve. Start engine. Apply 6-10 in. Hg to vacuum hose. If idle becomes unstable or engine stalls, EGR valve is functioning properly.
2. Check for adequate manifold vacuum. With engine warm and idling, connect vacuum gauge to port on vacuum amplifier leading to EGR thermovalve. Vacuum should not be greater than 1.6-2.4 in. Hg at idle.
3. Disconnect venturi hose at carburetor. Increase engine speed to 3500 RPM. Vacuum should not change. Maintain high engine speed and reconnect carburetor venturi hose.
4. Vacuum gauge should read 3.2-3.8 in. Hg. Return engine to idle. Vacuum gauge should return to initial reading. If vacuum gauge does not return to initial reading, replace vacuum amplifier.

1975-78 Capri II (Ported EGR Valve)

1. Check vacuum lines for correct routing. Disconnect vacuum hose at EGR valve and plug hose end. Connect a hand-held vacuum pump to EGR valve. Start engine. Apply 6-10 in. Hg to vacuum hose. If idle becomes unstable or engine stalls, EGR valve is functioning properly.
2. Remove hose between vacuum amplifier and EGR thermovalve. Connect a pressure gauge to hose. Remove hose from vacuum amplifier reservoir, and "T" into intake manifold vacuum.
3. Increase engine speed 1500-2000 RPM. Vacuum gauge should read greater than 4 in. Hg. Allow engine to idle. Vacuum gauge should now read less than .5 in. Hg.

1979-80 Fiesta (Ported EGR Valve)

1. Ensure engine is at normal operating temperature. Check vacuum lines for correct routing. Remove EGR vacuum supply hose from EGR valve and plug hose end. Connect a hand-held vacuum pump to EGR valve.
2. With engine idling, observe EGR valve stem while applying vacuum to EGR valve. Stem should start to move within 1-2 in. Hg. With engine off, apply a minimum of 8 in. Hg to EGR valve. Vacuum should remain within one in. Hg for a minimum of 30 seconds.
3. Start engine. Apply 8 in. Hg to EGR valve. If idle becomes unstable or engine stalls, EGR valve is functioning properly. Connect vacuum gauge to EGR vacuum supply hose. Increase engine speed 1500-2000 RPM. Vacuum gauge should read 8 in. Hg or more. If system operates as indicated, system is functioning properly.

1985-88 Merkur & 1991-93 Escort/Tracer 1.9L (Ported EGR Valve)

1. Check vacuum lines for correct routing. Ensure no vacuum is available to EGR valve with engine idling. Disconnect idle air by-pass valve connector.
2. Disconnect vacuum hose at EGR valve and plug hose end. Connect a hand-held vacuum pump to EGR valve. Start engine. Apply 5-10 in. Hg to vacuum hose. If idle becomes unstable or engine stalls, EGR valve is functioning properly.
3. Reconnect idle air by-pass connector. Connect a hand-held vacuum pump to EGR vacuum supply hose. Ensure engine is at normal operating temperature. Increase engine speed 1500-2000 RPM. Vacuum gauge should read greater than 5 in. Hg. If system operates as indicated, system is functioning properly.

1988-89 Fiesta & Tracer (Ported EGR Valve)

1. Ensure engine is at normal operating temperature. Check vacuum lines for correct routing. Ensure no vacuum is available to EGR valve with engine idling. Start engine. Place finger against EGR diaphragm. Increase engine RPM. Diaphragm should move.
2. Remove EGR vacuum supply hose from EGR valve and plug hose end. Connect a hand-held vacuum pump to EGR valve. With engine idling, apply 6 in. Hg to EGR valve. If vacuum holds and idle becomes unstable or engine stalls, EGR valve is functioning properly.

EGR Valve

1. Ensure all vacuum hoses are correctly routed and securely attached. Replace any crimped or broken hoses. Ensure there is less than one in. Hg vacuum to EGR valve at idle with engine at normal operating temperature.
2. Install tachometer. Disconnect Idle Air Control (IAC) wiring harness connector. Remove and plug vacuum hose at EGR valve. Start engine. Idle in Neutral. Note idle speed. Using hand vacuum pump, slowly apply 5-10 in. Hg vacuum to EGR valve. When vacuum is fully applied, engine should do one or more of the following: Engine should stall. Idle speed should drop more than 100 RPM. Idle speed should return to normal when vacuum is released.
3. Service or replace EGR valve if engine does not stall or idle speed does not respond as specified. Reconnect IAC harness connector. Unplug and reconnect vacuum hose at EGR valve.

EGR Vacuum Regulator (EVR) Solenoid

Turn ignition off. Disconnect EVR solenoid wiring harness connector. Measure resistance across EVR solenoid terminals. If resistance is not 26-40 ohms, replace EVR solenoid. For additional testing, go to CIRCUIT TEST HE in appropriate article.

Electronic EGR Valve

1. Connect vacuum gauge to valve. Start engine. Apply 6-10 in. Hg to EGR valve and hold. Engine speed should drop at least 100 RPM or stall. Vacuum should not drop greater than 1 in. Hg in 30 seconds.
2. Check vacuum lines for correct routing. Disconnect vacuum hose at EGR valve and connect vacuum gauge to hose. On 1.9L EFI, disconnect idle air by-pass valve. On all models, accelerate engine to 2000-2500 RPM and release throttle. Repeat 8-10 times and check for consistent response. NOTE: EGR Vent Solenoid (EGR-VSOL) allows a small amount of vacuum signal (less than 2.5 in. Hg) at idle.
3. If vacuum reading is greater than zero with cold engine, EGR solenoid is leaking and should be replaced. With engine at normal operating temperature, vacuum should be greater than 15 in. Hg and return to zero when throttle is released. If EGR system operates as indicated, system is functioning correctly.