what are egr port plugs, and how do i get to them to replace them? I came across an article talking about them getting plugged with carbon and the results were almost EXACTLY the same problem I'm having, and I'm pretty sure mine are plugged, because i can scrape chunks of black stuff out of my egr valve. I't said to get new plugs, and clean the carbon out before putting them in. Is it a really difficult job to do?

 

"EGR ports plugged" I would believe. More accurately, "EGR passages plugged". No such thing as "EGR port plugs".

You need to take the intake manifold off and clean the carbon out of the EGR passages.

 

hmm, ok i see, and I just noticed in the post I read the guy had a honda...maybe thats why he has plugs I dunno.. But what he said in this post is exactly how my car has been acting, here is his post if you or anyone else would be interested in it. it was news to me lol. either way hopefully i can clean out those passageways and get some kind of relief from this annoying problem.

Most of the problems I have read here describe a problem with the EGR, but not the EGR valve itself. It sounds as if your egr port plugs are clogged with carbon. By removing the plugs from the intake manifold (not easy) and cleaning out the plugged holes of carbon buildup and putting in new plugs will resolve this problem! This particular problem appears out of nowhere one day. It appears when you are shifting from a stand still at a light from first to second to third gear, under 2500 -3500 RPMs. The engine acts as if it's getting no gas/power at all and jerks a little like it's going to stall.
Usually, letting off the gas and then feathering the gas returns it to normal operating condition, but it will repeat once in a while out of the blue.
The intake manifold has EGR plugs in them. My 1992 Honda accord four-cylinder it has four front and two rear plugs in the intake manifold. they look like small round circles machined right on the manifold leading into the head, but they are actually plugs. The plugs themselves cost pennies each from your dealer. Some parts may have to be removed to gain access meaning a few more dollars for new gaskets depending on vehicle model.
Tip: don't forget to bend a soft wire etc, to scrape up under the inside of the hole, inside the manifold, and remember to vacuum out as much carbon and most importantly and especially any metal shavings as you can, use a small rubber hose taped to a vacuum cleaner.
Remember after you have assembled all, anything left inside gets sucked into the head, so be patient and through, and buy lots of extra plugs (they are only pennies) in case you lose some. Doing yourself takes time if you are careful. Tools are not too expensive, and parts are very cheap. But a quote from my dealer was 400-700 dollars stating each mechanic has their own special tricks to doing this.
I hope this helps. Before doing this I changed my fuel filter, plugs and wires, distributor cap and rotor, main relay, the EGR valve itself, etc., and still had the problem.
I finally found some threads online and changed these plugs and problem hasn't returned yet.
Hope this helps some of you and saves you some money. Thutch6624

 

On an old carbureted engine there is the possibility of getting the passages plugged up pretty bad with carbon. Only in one case did I find one plugged solid. Usually the valve gets clogged up before the passages.

Easy way to fix- remove the EGR valve and clean it as best you can. Then start the engine with the valve removed. When it fires up the RPMs will shoot to the moon (becuase you introduced a huge vacuum leak), so you don't want to run it long like this. Usually it will fire up, RPMs will sky and then it'll stall. That's fine- it only takes a few seconds.

The strong exhaust pulses will blow the carbon out of the exhaust side of the EGR system and the strong intake pulses will do similar for the intake side. Ta da! Clean passages. Unfortunately, a little clean up to do in the engine bay afterwards since it will blow little carbon chunks all over the place. No big deal. Clean up, reinstall EGR valve and away you go.