EGR Gas Flow Test

Note: EGR system must pass CONTROL SYSTEM TEST and GAS FLOW TEST to pass BAR 90 FUNCTIONAL TEST.

1. Connect tachometer.
2. Disconnect and plug vacuum hose to EGR valve and connect vacuum pump to EGR valve nipple.
3. Start engine and disconnect Idle Air Control (IAC) motor electrical connector.
4. Slowly apply vacuum to EGR valve.
5. Engine rpm should drop as vacuum reaches 2.0 to 3.5 inches Hg, and continue to drop as more vacuum is applied, engine may even stall.
^ Drop in rpm indicates exhaust gas is flowing through valve, vehicle passes GAS FLOW TEST.
6. If engine rpm does not drop when vacuum is applied to the EGR vacuum diaphragm, then a defective EGR valve, plugged EGR passage, or plugged tube is indicated. Remove EGR valve, and inspect intake manifold passage.
^ Clean passages if necessary, and retest.
^ If no obstructions are found in intake manifold passages, replace EGR valve and retest.

Note: If EGR system is functioning correctly, and CHECK Engine lamp indicates malfunction of EGR system, check on-board diagnostic system.