Outer Limits 4x4 Board

Hi all,

I'm working through my G16B engine management system fixing problems in a effort to improve economy. I've replaced a faulty VSV for the EGR system but no EGR activity.

The modulator is fine and tested okay according to haynes method.

Ive also pulled the EGR valve out and given it a clean (some carbon not too much) but i'm getting no flow from the exhaust outlet port cast on the back of the engine. Where does the exhaust gas come from? I assumed it was being diverted from somewhere between the exhaust valves and the ports on the head. I'm running extractors, have these blocked the system? If so can i get EGR compatible ones?

should the VSV open and close without the rest of the EGR system working?

I would guess that the VSV dying has allowed the passage to become blocked. Is there a good method for cleaning the EGR passage(on the exhaust side). I had planed to use CRC cleanRcarb and some thin wire. Anyone know the diameter of the passages or can check on a spare head/block?

Cheers

Adam

the gas is taken from number 4 exhaust port on the manifold. and the cavity that runs across the head to the inlet manifold is famous for gumming up with carbon.

joeblow wrote:the gas is taken from number 4 exhaust port on the manifold. and the cavity that runs across the head to the inlet manifold is famous for gumming up with carbon.

Ya, Ive cleaned out the outlet that runs across the back of the head (side show bobed some coax and ran that through with cleanRcarb. Ive also sent some through the inlet side. Apart from that the only problem ive got is a slightly leaky EGR valve (wont stay shut when the car is running = constant trickle of exhaust gas into system)

The flange on my extractors has blocked up the port on the head that the exhaust gas goes down. I might chat with my exhaust guy while he is putting a resonator on (Mrs says zooks 2 loud with its 2" system ) and see if he can make a small elbow peice and re-connect the port. With a cat still on i should still have enough back pressure to open the EGR valve.

Does anyone have a stock exhaust manifold around. I'm keen to know what the diameter of the EGR port is at both the #4 exhaust port and EGR port ends

i got a stock one here.

off my front cut. its only the bit from the flange to the head.

going by joe's description I'm looking for a hole somewhere inside the exhaust manifold port for cylinder #4 which will lead to a small (maybe 10-12mm diameter port on the flange.

Plan B is to drop by suzukishop in cannington with my vernier caliper and measure one.

ahh yes. aftermarket extractors usually don't have the link between number 4 port and the chamber for the egr. i've done many where i have drilled new holes and added a section of pipe to join them.

joeblow wrote:ahh yes. aftermarket extractors usually don't have the link between number 4 port and the chamber for the egr. i've done many where i have drilled new holes and added a section of pipe to join them.

yep thats precisely what i intend to have done. normal EGR function has been restored afterwards???

I would have thought it would not be that hard for the header manufacturers to put EGR on for the g16's given they make em with egr for the g13s!

it should be fine, i've had to do that mod when i take vehicles for sniff tests for engineers reports.

I've mesaured the port up on a stock manifold (10mm ID) and checked that it just comes of the side of the port right up close to the flange.

My exhaust guy has said that he can put a pipe on my extractors for the EGR but needs to have a template to work from. Has any one in Perth got a spare G16b head (pref. a badly cracked or corroded one) that I could borrow (NOR or SOR is fine). i'm happy to donate a bottle to anyone who can help.

Cheers