EGR Function Testing Subaru Justy I

EGR VALVE

1. Look through opening in EGR valve body. With engine at normal operating temperature, check that valve shaft moves when engine reaches 3000-3500 RPM under no-load condition.
2. If shaft does not move as specified, remove valve and manually check valve movementfc. If valve appears okay, check vacuum lines for leaks. If valve does not operate, clean or replace. NOTE: When cleaning EGR valve, DO NOT wash in solvent or degreaser or permanent damage to the valve diaphragm will result.
3. While holding valve assembly by hand, lightly tap on sides and end of valve with plastic hammer to remove exhaust deposits from the valve seat. DO NOT place unit in a vise.
4. Using wire wheel, buff the exhaust deposits from around mounting surface and valve. Depress valve diaphragm, look through valve outlet and inspect valve seat area for cleanliness. Repeat cleaning operation if not completely clean.
5. Inspect valve outlet for deposits and clean as necessary. Blow clean with compressed air. Recheck valve operation by applying 7.87 in. Hg with a hand vacuum pump. Install unit using a new gasket.

EGR SOLENOID VALVE

1. Remove connector from solenoid valve. Measure resistance between solenoid valve terminal leads. Specified resistance is 32.7-29.9 ohms. If measurement is out of specifications, replace solenoid valve.
2. If resistance measurement in step 1) is okay, measure resistance between solenoid valve terminal leads and body ground. Specified resistance is 1000 ohms or more. If measurement is out of range, replace solenoid valve.
3. Check vacuum passage for opening and closing operation while applying electric current to positive and then negative terminals. If solenoid valve does not operate properly, replace with a new one. If solenoid operates properly through all tests, valve is normal.

Scheme 23

1. Remove valve from intake manifold. Connect hoses to the output ports for air cleaner and EGR valve (2 upper ports) and plug output port to canister (one lower port). (Scheme 23) Submerge valve into a container of cold water. NOTE: DO NOT allow water to enter valve.
2. Heat slowly to raise temperature of water. Blow air into valve and confirm valve opens or closes in response to water temperature.
3. Thermo vacuum valve should completely open below 86°F (30°C) and should completely close above 104°F (40°C). Remove thermo valve from water. Connect vinyl tubes to output ports to EGR valve and canister, and plug output port to air cleaner with a cap.
4. Blow air into valve and confirm that valve opens and closes in response to water temperature. Valve should completely open below 86°F (30°C) and should completely close above 104°F (40°C).

Multi-Point Fuel Injected Engines

Ensure there is no air flowing from EGR solenoid valve side, to air intake boot side. Ensure there is air flowing from air intake side to EGR solenoid valve side.

EGR SYSTEM

1. If both EGR valve and thermo vacuum valve are functioning correctly, apply about 7.87 in. Hg to EGR valve with hand vacuum pump. With engine warmed up, either rough idling or engine stall should occur.
2. If engine idle does not change, check EGR pipe and gas passages for clogging and leaks. Clean or replace if necessary. When cleaning, inspect EGR gas inlet to intake manifold for presence of deposits.
3. Remove any deposits present using a hooked awl. Take extreme care that deposits DO NOT fall into intake manifold. DO NOT use an electric drill for cleaning. Remove deposits using a vacuum device.
4. Inspect EGR gas inlet pipe for exhaust deposits and remove pipe as needed. Tap lightly on sides of pipe to loosen deposits. Clear deposits in pipe by using compressed air. Reassemble and install pipe.