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Think your car's EGR valve is defective? Every modern car is equipped with an EGR valve. When it's clogged or damaged, the engine runs rough.

Now, if you're completely new to the automotive world, or haven't spent much time tinkering with your toys, you may not have heard of the EGR. This is where most mechanics can try to take advantage of vehicle owners.

Symptoms of a faulty EGR valve include: poor engine performance, a check engine light, an unburned fuel smell coming from the exhaust, a failed emissions test, and rough idle.

egr

How do you know if your EGR is really bad? And what could be the reason? You'll also learn everything there is to know about this simple but complex vehicle component, so let's get right to it.

5 symptoms of a bad EGR valve?

EGR faults can cause a lot of problems. The vehicle's fuel economy is affected, for example, and this will result in high fuel consumption by the vehicle, increasing the risk of carbon deposits, higher emissions, faulty injectors and damaged sparks.

So it's really essential that you get a faulty EGR checked as soon as possible. While there can be a lot of bad symptoms, here are the main red signs that tell you your EGR valve needs a checkup.

1) Poor engine performance

There are a lot of issues when it comes to bad EGR valves and the first and perhaps most frustrating issue is engine performance. Chances are you'll experience difficulty accelerating and even an overall reduction in engine power when you press the gas pedal. This can also happen because of a poor fuel filter

This can happen because the air-to-fuel ratio is very rich or very lean[1]. Because of this, the engine may require more fuel than normal in almost any situation you encounter while driving. This will really take a toll on your wallet as fuel prices are not showing any signs of decreasing either

2) The engine warning light

You should always check the engine warning light, which in most cases will light up on the dashboard if the EGR valve fails in any case (unless you've also damaged it in some way, in which case you'll need to replace it as well).

We won't get too technical here, but just know that the engine warning light comes on when the ECU detects problems with the engine or its directly associated components.

The EGR is directly connected to the engine, so any irregularities in its operation (opening, closing, etc.,) will be immediately detected by the EGR valve sensors.

3) Unburned fuel odor

Now that the EGR valve is not working properly, the engine is burning more fuel than it should, which will eventually cause more hydrocarbons to exit the exhaust pipe. This will increase the amount of fuel odor, so much so that you can smell it inside the car if your air conditioner is not on recirculation mode.

This is very irritating and can be terrible for your health. It is a sure sign that something is wrong with the engine.

4) Emissions Test Failure

If you are in a situation that requires you to test for increased emission levels every 6 months, you may have a faulty EGR valve. While this test may not accurately predict the condition of the EGR, if you fail your emissions test, it is healthy to have the vehicle's EGR valve checked by a professional.

5) Hard Idle

Rough idling occurs when the engine has a defective EGR valve. In this case, the valve will remain stuck in the open or closed position until the problem is resolved. It could also be an indication that there is too much exhaust gas entering the combustion chamber.

This will disrupt the air/fuel mixture necessary for proper engine idling. You will notice a fluctuation in the RPM needle as the car struggles to maintain RPM at idle.

The EGR valve stuck in the open position creates a vacuum leak that causes inefficient combustion. A valve stuck in the closed position increases nitrogen oxide emissions, which disrupts engine timing, resulting in engine knocking.

Read also: 5 Symptoms of a Bad Front or Rear Differential and Repair Cost

What is an EGR valve?

The EGR valve or exhaust gas recirculation valve is found in most modern fuel vehicles (gasoline and diesel), and the purpose of these things is to help reduce engine emissions, by "recirculating" some of the exhaust gas back into the engine.

In recent years, it has been proven that there has been drastic climate change due to pollution, and the contribution of cars to this pollution is very high.

The government in turn has set certain regulations for car manufacturers, and one of them is the addition of EGR. So almost every vehicle you see on the road today probably has EGR in it. 

Benefits of an EGR valve

An EGR valve will significantly reduce temperatures in the cylinder. Without getting too technical, here's a quick operating principle on how engines work - they essentially suck in air and mix it with fuel at a certain temperature and pressure, and this mixture is then ignited to produce energy that moves the vehicle's wheels.

 With the help of an EGR valve, some of the exhaust gas can pass through the intake manifold where it displaces some oxygen from the air, keeping the engine cooler and more efficient.

The high temperature and excessive oxygen are the main sources of NOx (exhaust gas pollutants) formation. And from the above observation, it can be clearly stated that an EGR effectively reduces both the excess oxygen content and also reduces the engine temperature.

It also helps to reduce the amount of nitrogen emissions produced. Exhaust Gas Recirculation (EGR) is one of the simplest techniques that can be easily applied to eliminate NOx formation.

How does EGR work?

There is a lot of air around us that is captured by the engine's intake manifold. The air is made up of about 20% oxygen and 80% nitrogen. There are also other components present in very small amounts, but the main reactive components are oxygen and nitrogen. Learn how to care for a turbocharged engine

What is the purpose of an EGR valve? While oxygen reacts with the fuel, at high temperatures (about 25,000F inside the engine), nitrogen burns to form increased NOx emissions. The role of EGR here is to return the gases that are vented into the combustion chamber to reduce the temperature and also to suppress NOx formation almost entirely.

EGR system technology has evolved over time

Modern diesel and gasoline vehicle engines use a range of EGR valve configurations. Before learning what causes EGR problems, it would be best to know what type of EGR your vehicle has, so that the problem can be further reduced with relative ease.

Older Vehicle Models

In older generations of vehicles, EGR valves would take up more space due to their thick round design. They are typically made with a 3-inch diameter and are located on the top of the engine.

On these older models, there is a suction pipe that operates the EGR valve. A tube serves as the connection between the top of the EGR and the carburetor. The metal disc is inside the valve, containing a vacuum diaphragm, piston and spring configuration.

Semi-modern vehicle models

Most manufacturers in the last decade have an electronic vacuum EGR valve that is placed inside a cylinder or small block in some cases. The valve is designed in such a way that it operates in the same manner as those that were fitted to older models.

This can go unnoticed because instead of tubes, electronic solenoids are also connected through the vacuum lines and the valve. This helps the EGR position sensor communicate faster and more efficiently with the ECU.

Three EGR valve faults:

There are only 3 types of faulty EGR valves, and each has different symptoms. The EGR valve can become faulty in two different ways. It can either stay closed all the time, or it can stay open all the time.

There are also cases where it can stay clogged in the off position due to all the unburned carbon deposits. So let's review these problem cases and learn how to diagnose them.

Read also: Top 10 Signs of Alternator Problems

1) When the EGR valve is stuck in the open position

In a case where the EGR valve is in the open position, chances are it will create a vacuum leak. This leak will cause incomplete combustion, which is usually the initiator of rough idle and fluctuating RPM needle.

Diagnosing EGR Locked in Open Position

When the vehicle is parked in the idle position, what you need to do is look for a piston shaft and physically check the positioning of the valve. If this is not a feasible option, there are several OBD or on-board diagnostic devices (more on this later) that can be plugged into the vehicle and checked for errors.

Error codes such as P1406 and P1404[2] can be seen in cases where the valve is stuck in the open position. You will need to remove the plug and fill the empty spaces with carbon cleaner.

In other cases, if the working fluid inside the EGR is leaking when the world is placed upside down or when it is held open, all you have to do is use a valve cleaning kit and then move on to vacuuming the valve. .

2) When the EGR is stuck in the closed position

As we discussed earlier, if the EGR is in the closed position and remains blocked, a large amount of NOx emissions are not far away. This type of vehicle can even produce shocks[3]. This will cause another type of disturbance in the engine timing and, of course, lead to excessive wear. This is certainly not something we want.

Diagnose a stuck EGR valve in the closed position:

In the parked position if the car is revving up, always check for a moving EGR valve. When the EGR is stuck closed, errors P041 and P1406 may appear on the OBD ECU analysis tool.

The knocking noise you may hear may be a sign that the valve has already been closed. You will need to remove the valve manually. A valve kit at this point will come in handy, or you can always go to your mechanic if you don't want to get your hands dirty.

3) Clogged EGR valve

Unburned carbon deposits can also prevent EGR valves from staying in an ideal position. This kind of problem can lead to a rough idle. This can only happen in severe cases when the automobile is in its starting position. Clogged EGR valves prevent exhaust gases from recirculating, and this usually occurs after traveling at speeds of 30 mph (45 km/h).

How To Clean an EGR Valve Without Removing It

Diagnosing and Repairing a Clogged EGR

Errors P1404 and P1406 are displayed on the ECU analysis tool indicating that the EGR valve is blocked. All you have to do is remove the valve and clean it with a valve cleaning kit or throttle body cleaner to remove the debris.

If you don't think you have the experience to fix the problem or if you can't get your hands on the proper equipment, the assistance of a mechanic is probably the best idea.

Smog testing is also a good way to detect a clogged EGR valve

If the EGR valve becomes clogged or completely blocked, it can no longer re-burn harmful emissions inside the combustion chamber. NOx emissions will flow uncontrolled through the combustion chamber and out the exhaust pipe.

Excessive NOx emissions will show up in a smog test and cause breakdowns. In addition to NOx emissions, a clogged EGR could enrich the fuel mixture and produce excessive amounts of HC (hydrocarbons) and CO (carbon monoxide).

Check engine light for diagnosis

A clogged or faulty EGR valve will trigger a "Check Engine" or "Emission Control" light on the instrument panel. The owner will need to take the vehicle to a certified test and repair station that has a code scanner (OBD diagnostic tool).

The scanner will then be plugged into the vehicle's computer system and a trouble code will be identified. If the EGR valve is the system failure, the code number will specifically identify the EGR as the failed component.

When the engine overheats because the EGR has failed, more lube oil can potentially enter the combustion chamber and the diesel engine can begin to run on lube oil even if the fuel supply is shut off. A diesel engine may then begin to run on its engine oil instead of fuel.

The driver may not be able to stop the engine other than by forcefully stalling it. Eventually, the engine sucks up all the lubricating oil and the engine may disintegrate.

Cost of EGR Valve Repair/Replacement

Most EGR valve problems can be solved simply by cleaning it with a throttle body cleaner. Cleaning the carbon build-up should make it run smoothly without getting stuck in the open or closed position. So, you'll need some elbow grease and a throttle body cleaner to do this 20-minute job.

Can you drive with a bad EGR valve?

A stuck EGR valve can cause the engine to slam, which will soon destroy it. Based on the performance issues you described, it appears that the EGR valve pivot sometimes stays in the open position. EGR should generally only occur under low load, highway speed driving conditions. 

Safety Tips:

Most mechanics will probably be willing to replace an EGR easily, as it usually doesn't require much technical expertise. But if you ever encounter the problem of having to do it yourself, be sure to use proper safety precautions and procedures throughout the operation.

It's a good practice to take pictures of the engine compartment and EGR valve connections.

The EGR cooler should be allowed to cool and then disconnected from the battery. You will need to wait a few minutes for the electrical system to fully discharge or you risk a mild shock, or worse, damage to the battery.

The process of isolating the battery terminals must also be done to avoid shorting (remove the negative terminal first, then the positive terminal to avoid the risk of shorting but accidentally touching the positive terminal to the chassis). But before you remove anything you should check the replacement EGR valve you bought. It may look identical to the old one, with the same connections and also the fittings, as most EGR valves have the same configurations. 

The EGR valve may also have vacuum hoses. Before you forcefully twist and remove the hoses, be sure to label them. Most manufacturers already have them labeled, but in case you don't see a label, correct one.

Be very careful not to break them or even stretch them too much. If they have been cracked or damaged, you need to make sure you replace them with newer replacements. These pipes are not rare and they are not that expensive either, so it is best that you buy new ones.

Once this is done, you need to carefully remove all electrical connections. This can easily be done by hand, as most of them are simply tightened by hand.

The valve can be mounted with a robust outer body, while also being bolted to the cylinder head. This is because it has hot exhaust gases flowing through it at all times. The bolt that holds the valve can end up being particularly tight as a result. It may be a good idea to pre-spray it with a lubricant such as WD40[4] and let it sit for a few minutes.

Once you have successfully applied the degreaser to all the bolts, use force to remove the valve and body with your hands. Chances are the valve will get stuck, but it should come off with a little push and pull.

Next, you should carefully remove the remnants of an old gasket between the valve body and the cylinder head and clean the interface without allowing debris to fall into the cylinder head in any way if possible.

A new gasket should then replace the old one, and it should be matched with the new valves. A good practice would be to use a small amount of high temperature resistant silicone sealant.

In order to put the valve back into the engine, simply repeat the entire process in reverse. It may be necessary to reset the check engine light before starting the car and make sure it idles smoothly before driving.

Final Thoughts

The exhaust gas recirculation system is perhaps the most important component of the automotive engine. If you understand how it works, it will be easy to ensure that it is always kept in good condition, which can otherwise cause a lot of problems, so it is essential to keep your EGR valve clean and trouble free.

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