I keep getting a 2-4-1 message EGR valve malfunction on my '94 85 Turbo Wagon. Does anyone have experience in replacing this expensive part, or is there another issue? I also seem to have smoke coming from that area when the engine is warm. I have replaced the Flame trap about 5,000 miles ago. It also smokes out the dipstick tube when it's warm.
Any ideas?
Thanks,Tim

 

the port where the EGR valve attaches to the intake manifold is likely plugged. You need to remove the valve and clean out the port with solvent and a brush. Actually, you probably need to change the PCV system as well- this is the smoke issue, particularly out of the dipstick tube- pressure is building up in there, and forcing blow- by gases out of the tube instead of it being sucked through the PCV system. The flame trap is part of the PCV, but there's also an oil trap that gets plugged. There's plenty of write- ups on doing this. Basically, you have to remove the intake manifold to do the PCV, and that makes access to the EGR port much easier, so do it all in one fell swoop, and you'll make your engine a lot happier. Allowing the PCV system to remain clogged can eventually result in seal failure and massive oil leaks, requiring extensive work to repair. So get on this soon. Good luck!

 

+1 (Can be done yourself with time)

 

I ordered all the parts today. I'll give a update when I'm done. Thanks for the reply's. Tim

 

Mostly all back together. EGR was totally plugged, manifold, gasket, and valve, Brake cleaner and picks got it all clean. Oil Smell was from the hose going from Flame trap to Intake Hose was broken in many places and leaking out of the foam seal. Also hose to head was leaking. Changed Plugs and Compression was 135 all accross. Just waiting for New Intake hose to come in Monday and I will be back on the road. I miss my heated seats ...
Tim

 

Compression was 135 all the way across? That's not good... factory calls for 156-185. do the check again after the engine is warm. Remove all spark plugs, make sure the battery is good, and hold the throttle open while cranking- crank the engine at least 5 turns for each cylinder. If you don't reach at least 156, something is worn out, likely rings. To verify this, pour about a tablespoon of oil into a cylinder and check compression again. If it improves, your rings are worn. Good luck!

 

It was stone cold with the intake off and all the plugs removed. That might explain the excesssive Crankcase pressure also...

 

All back together and running well. I would add checking the EGR valve port to anyone who is doing the PCV system. Real easy when the intake manifold is on the bench!!
Tim

 

Good to hear Tim.

 

It's good to know that you have already done it. The EGR malfunction happened to me last week and it is still not fixed cuz the EGR valve I have ordered hasn't arrived yet.