A little back story...I've owned this car since 02. Since about '04-05 I've gotten an intermittent EGR code, never really cared. I finally decided that I was going to see if I could fix it. I pulled off the plenum, and runners, and replaced those gaskets since I was in there. I'm 99% sure they are on correct at this point. Anyway, I found that the EGR passage in the plenum was completely clogged. Three cans of throttle body cleaner, and I had a pin hole through it. I finally figured out that it was clogged right behind the 1/4 walls, just behind the throttle body. Took a small pick, and managed to get through the carbon there. Got it cleaned up, and I was hoping that it would take care of my EGR issues, so I put it back together. Fired the car up, and it barely idles, and I can hear vacuum sucking. I didn't have any carb cleaner to start checking for leaks yet, but my question is, can a bad EGR valve cause enough of a vacuum leak for it to be audible? If I track this thing down to the valve, I'm not sure If I'm going to replace it, or just buy a block off plate.

Also...when I had the plenum off, I did move the EGR valve, and it was incredibly stiff, but it did move, and felt like it returned to normal position. Not sure if that will matter, but thought it might be work mentioning.

 

It sounds like you might have un lodged a piece of carbon that is now holding open the egr pintle. If you do decide to get rid of the egr send me a pm, I offer reprograming to disable the egr function and code 32.

 

PM sent for some more info. Thanks

 

make sure you hooked the EGR vac line back up to the bottom of the throttle body

 

Yep...verified vacuum line to the bottom of the throttlebody, and to the top of the EGR valve.

 

I've had my IROC since 2000, and i've had an intermittent egr code since i got it. This is thru 2 engine rebuilds, and 3 separate EGR valves!! I finally had TP just eliminate the code completely, and now I don't worry about it anymore.

 

Well, I pulled the upper intake apart again...got new fuel injectors from Southbay. When I pulled the runners, I noticed the 9th injector mounting point was "tweaked" and it didn't fit right. Corrected that, and while I had it down, I hooked vacuum to the EGR valve to check it. It held vacuum pretty well, and actuated smoothly. I ended up leaving the EGR valve alone at this point, finished swapping the injectors. I believe that my problem was that the 9th injector wasn't sealing correctly. Now that it is, it seems to be idling just fine, and I can no longer hear the vacuum leak.