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TPI Aftermarket EGR Solenoid Installation

Old 01-21-2019, 11:29 PM
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TPI Aftermarket EGR Solenoid Installation

As you may or may not be aware, you can not obtain new OEM EGR solenoids for our TPI cars. This became pertinent to me as I failed CA smog with high NOx.

When I failed smog I tore into my EGR system to discover the solenoid virtually falling apart. The hard line had also seen better days. That would explain some occasional light-throttle stalls I had seen.


Bad TPI EGR Solenoid

I decided to just replace anything and everything EGR related so I did not have to worry.

There have been several posts about using VS25 solenoids to replace TPI ones, but there wasn't anything to help with visualization that I saw.. so I took pictures and documented the process.

Parts Required
(1) Standard Motor Products VS25 EGR Solenoid
(1) Painless Performance 70402 Weatherpack Connectors 2-Wire Kit
(1) 92-97 LT1 Camaro/Firebird/Corvette EGR Solenoid Wiring Harness Connector Plug
(1) Dorman Hard Emissions Tubing 47418
(3) L Vacuum Connectors
(1) Strait Vacuum Connector


While I was in there I also replaced the EGR Valve and EGR Temperature Switch...
(1) ACDelco EGR Sensor Switch 212-336 (Since it is for a Corvette, I had to lengthen the wire. I found a NOS one and I'm sure there's a vette guy shaking his fist at me)
(1) ACDelco EGR Valve and Gasket 214-5538

To remove the old solenoid, you have to find it first. It's hidden way under the ignition coil, left-side of the engine bay, back by the distributor. It's actually mounted with the 2 bolts holding the coil mount. Simply (hah) un-bolt the 2 coil mount bolts.

Disconnect the EGR solenoid wiring and 2 vacuum lines. Remove Solenoid. Reattach ignition coil mount with the 2 bolts.

Now, you could mount the new one there, but I did not want to try to wrestle with trying to run vacuum hose down there. Instead I decided to mount it on the fuel rail with the fuel rail bolt.

To do so, I had to modify the VS25 solenoid mount a tad. First I tapped out the bolt that is in the mount. I just laid it over a socket and tapped it out with a small hammer. I enlarged the hole to accommodate the fuel rail bolt. I bent off the small protrusions on the mount as well.


VS25 EGR Solenoid mounted to the TPI fuel rail

After that, I made an adapter for the old EGR solenoid connector to connect it to the new solenoid. Wire orientation does not matter. Plug and play, no messing up your harness.


TPI EGR Solenoid to LT1 style adapter

Then it was a matter of connecting the vacuum lines. The shiny nipple on the solenoid goes to the vacuum source (throttle body,) while the black plastic nipple goes to the EGR valve itself. Here's the routing I ended up with.


VS25 EGR Vacuum Diagram

After that I buttoned everything back up. It looks pretty decent, plus it won't be such a chore to change if it ever needs swapped again.


VS25 EGR Solenoid final installation

Hitting smog again tomorrow, so I'll post up results. The car ran fine and threw no codes, so fingers crossed!

Last edited by thtanner; 01-22-2019 at 01:28 AM.
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Old 01-22-2019, 10:54 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Thanks for the great info and part numbers. Ill definitely be keeping up with how your smog goes. Also from california and i plan to restore evry part i can once i do my engine swap to keep up on emissions here in CA.
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Old 01-22-2019, 11:13 AM
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Re: TPI Aftermarket EGR Solenoid Installation

If you can’t find a good f body solenoid. A y body works well. It mounts to the t stay housing.
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Old 01-22-2019, 11:23 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Is that Solenoid normally open or normally closed?
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Old 01-22-2019, 11:47 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Dyno Don View Post
Is that Solenoid normally open or normally closed?
Should be same as the TPI solenoid. According to tealman its normally open.

The LT1 solenoid can't be used I have read. This is originally from a 90-95 DeVille with 4.9L.

Last edited by thtanner; 01-22-2019 at 02:06 PM.
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Old 01-22-2019, 01:56 PM
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Re: TPI Aftermarket EGR Solenoid Installation

A tpi solenoid is NO normally open. The lt1 solenoid is NC like a tbi car.
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Old 01-22-2019, 02:05 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by tealman92 View Post
A tpi solenoid is NO normally open. The lt1 solenoid is NC like a tbi car.
Roger that. The VS25 is same as the TPI one so assuming NO then

Car is about to hit the Dyno now for smog. Fingers crossed.
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Old 01-22-2019, 03:15 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by thtanner View Post
Roger that. The VS25 is same as the TPI one so assuming NO then

Car is about to hit the Dyno now for smog. Fingers crossed.
oh man let us know how it goes. I have smog in March in Sacramento so im praying .
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Old 02-08-2019, 08:19 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Update: The EGR setup I posted does indeed work. Verified with a vacuum gauge off a T at the EGR valve.

I did fail smog again, but just found my timing was set to 10 BTDC (after testing the EGR stuff 100 times over.) That'll cause high NOx for sure. Going in for a retest as soon as tomorrow.
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Old 02-12-2019, 02:46 PM
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Re: TPI Aftermarket EGR Solenoid Installation

...
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Old 02-12-2019, 02:50 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Did you end up passing with 6 degrees of timing ?
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Old 02-12-2019, 11:35 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tuned Performance View Post
Did you end up passing with 6 degrees of timing ?


Unfortunately not, but it did cut NOx in half to 950ish. EGR and solenoid working good. Clear of obstructions, so I'm going to give the EGR system a clean bill of health right now.

That being said I datalogged my car and my BLMs are not looking too awesome. 108 at idle, definitely under 128 moderate cruise. It's obviously rich and I wonder if the computer is correcting on the lean side? (I say that because NOx is usually a sign of hot combustion temps which can be caused by lean conditions. As if you don't know that though heh)

New plugs, NTK o2 sensor tomorrow. Datalog and tuning thereafter.

Last edited by thtanner; 02-13-2019 at 12:03 AM.
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Old 02-14-2019, 11:19 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Did you change the injectors?
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Old 02-14-2019, 11:43 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tootie Pang View Post
Did you change the injectors?
Yes took out Bosch 3 and put in Delphi.
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Old 02-14-2019, 12:42 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Has it always run rich since the injectors have been swapped out ?
stock tune ?
Iirc your engine is pretty stock with truck tbi heads.
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Old 02-14-2019, 01:01 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tuned Performance View Post
Has it always run rich since the injectors have been swapped out ?
stock tune ?
Iirc your engine is pretty stock with truck tbi heads.
Probably.

Stock tune, truck heads heads and cam. Either Delphi flow more than 22lb at stock pressure or my head's and cam are weak enough that 22lb is rich. If I had an AFPR and the state allowed it I could just drop pressure a tad probably.
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Old 02-14-2019, 01:11 PM
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Re: TPI Aftermarket EGR Solenoid Installation

A afpr can only drop to stock 3 bar. I can’t imagine why it’s rich stock engine. You might have to tune for the injectors. If you can’t find the offsets you can adjust the maf tables.
https://www.thirdgen.org/forums/atta...air-flow-tuned
High HC at idle ?
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Old 02-14-2019, 03:49 PM
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Re: TPI Aftermarket EGR Solenoid Installation

You need a tune. I put in Bosch D3's and an AFPR on a bone stock, refreshed 89 LB9, set it all up and it was terrible. Got a tune and wow. The 19lb D3's were more like 24lb. Engine feels great now and passed smog with flying colors.
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Old 02-14-2019, 03:55 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tootie Pang View Post
You need a tune. I put in Bosch D3's and an AFPR on a bone stock, refreshed 89 LB9, set it all up and it was terrible. Got a tune and wow. The 19lb D3's were more like 24lb. Engine feels great now and passed smog with flying colors.
where did you get the offset information?
was the constant injector flow changed or just offsets ?
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Old 02-14-2019, 04:21 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tuned Performance View Post
A afpr can only drop to stock 3 bar. I can’t imagine why it’s rich stock engine. You might have to tune for the injectors. If you can’t find the offsets you can adjust the maf tables.
https://www.thirdgen.org/forums/atta...air-flow-tuned
High HC at idle ?
Sadly they do not test at idle so no idea if HC is high then. It's within limits at 15/25mph.

That link is awesome.

Slapping in the fresh o2 sensor and plugs in tomorrow. I have a PROM that has the injector constant changed from 22lb to 23lb, gonna datalog after and go from there.
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Old 02-14-2019, 05:03 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tuned Performance View Post

where did you get the offset information?
was the constant injector flow changed or just offsets ?
Man you got me, I don't about all that stuff. I worked with Scott. He said these act like 24 lb injectors. He backed off the richness incrementally. Took 7 iterations.
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Old 02-14-2019, 05:28 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Iím curious how one #hr constant will effect blm. I always set the injector flow rate and make adjustments to the maf tables for rich or lean conditions.


19s flowing like 24s makes my eyes water just thinking about it. Pretty gassy

Last edited by Tuned Performance; 02-14-2019 at 05:32 PM.
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Old 02-14-2019, 05:58 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tuned Performance View Post
I’m curious how one #hr constant will effect blm. I always set the injector flow rate and make adjustments to the maf tables for rich or lean conditions.


19s flowing like 24s makes my eyes water just thinking about it. Pretty gassy
I'll follow up with some comparative BLM readings (similar load/gear/speed/rpm)
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Old 02-14-2019, 06:41 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Some tunes $6e mask. I’m not sure what the broadcast codes are but I know the vette arap has lean cruise mode enabled. You said your cruising is 128. This might change when you install the 23#hr tune. You should see leaner than 128 cruising.
If you decide to tune out the rich condition buy a moates.net burn 2. Depending on your memcals if they have been fitted with the newer sst eeproms you can use a hdr1 and flash directly. If you choose to go the diy way send me a pm I’d be happy to look at your datalogs and revise your tunes.



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Old 02-14-2019, 06:59 PM
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Re: TPI Aftermarket EGR Solenoid Installation

I'm not at 128 at cruise, sitting 118-122, goes richer as load reduces it seems
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Old 02-14-2019, 08:14 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by thtanner View Post
If I had an AFPR and the state allowed it...
Huh? I've never had an issue having an AFPR. Had one on my GTA for nearly twenty years.
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Old 02-14-2019, 08:16 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by blacksunshine'91 View Post
Huh? I've never had an issue having an AFPR. Had one on my GTA for nearly twenty years.
It's a visual check failure.

These are old cars, and some smog techs probably don't even know what they're looking at anymore.
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Old 02-14-2019, 08:49 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Unless they were specifically looking to be a jerk, I doubt any tech would ever fail you for that. Most of them don't even know where to look for it, especially if you have the plenum extension on there.
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Old 02-15-2019, 01:06 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Tuned Performance View Post
Iím curious how one #hr constant will effect blm. I always set the injector flow rate and make adjustments to the maf tables for rich or lean conditions.


19s flowing like 24s makes my eyes water just thinking about it. Pretty gassy
LOL. I didn't ask for much info but what he said he was doing was backing off the injectors and then he was going to hit the MAF tables. But on the last one, he said we got it. I don't know if he needed to mess with the MAF tables.
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Old 02-17-2019, 10:23 PM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by thtanner View Post
It's a visual check failure.

These are old cars, and some smog techs probably don't even know what they're looking at anymore.
Yeah, they were trying to unhook a hose for the vac advance to check timing on my TPI last time I had it at a smog station... ended up unplugging the EGR somehow.

And thanks for the part numbers to get a new EGR solenoid in one of these. I happened to have a Corvette one laying around and stuck that in place of my old dead one, but the vette one is a bit crusty looking too so I've been looking for a new one.

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Old 03-15-2019, 01:50 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by thtanner View Post
As you may or may not be aware, you can not obtain new OEM EGR solenoids for our TPI cars. This became pertinent to me as I failed CA smog with high NOx.

When I failed smog I tore into my EGR system to discover the solenoid virtually falling apart. The hard line had also seen better days. That would explain some occasional light-throttle stalls I had seen.


Bad TPI EGR Solenoid

I decided to just replace anything and everything EGR related so I did not have to worry.

There have been several posts about using VS25 solenoids to replace TPI ones, but there wasn't anything to help with visualization that I saw.. so I took pictures and documented the process.

Parts Required
(1) Standard Motor Products VS25 EGR Solenoid
(1) Painless Performance 70402 Weatherpack Connectors 2-Wire Kit
(1) 92-97 LT1 Camaro/Firebird/Corvette EGR Solenoid Wiring Harness Connector Plug
(1) Dorman Hard Emissions Tubing 47418
(3) L Vacuum Connectors
(1) Strait Vacuum Connector


While I was in there I also replaced the EGR Valve and EGR Temperature Switch...
(1) ACDelco EGR Sensor Switch 212-336 (Since it is for a Corvette, I had to lengthen the wire. I found a NOS one and I'm sure there's a vette guy shaking his fist at me)
(1) ACDelco EGR Valve and Gasket 214-5538

To remove the old solenoid, you have to find it first. It's hidden way under the ignition coil, left-side of the engine bay, back by the distributor. It's actually mounted with the 2 bolts holding the coil mount. Simply (hah) un-bolt the 2 coil mount bolts.

Disconnect the EGR solenoid wiring and 2 vacuum lines. Remove Solenoid. Reattach ignition coil mount with the 2 bolts.

Now, you could mount the new one there, but I did not want to try to wrestle with trying to run vacuum hose down there. Instead I decided to mount it on the fuel rail with the fuel rail bolt.

To do so, I had to modify the VS25 solenoid mount a tad. First I tapped out the bolt that is in the mount. I just laid it over a socket and tapped it out with a small hammer. I enlarged the hole to accommodate the fuel rail bolt. I bent off the small protrusions on the mount as well.


VS25 EGR Solenoid mounted to the TPI fuel rail

After that, I made an adapter for the old EGR solenoid connector to connect it to the new solenoid. Wire orientation does not matter. Plug and play, no messing up your harness.


TPI EGR Solenoid to LT1 style adapter

Then it was a matter of connecting the vacuum lines. The shiny nipple on the solenoid goes to the vacuum source (throttle body,) while the black plastic nipple goes to the EGR valve itself. Here's the routing I ended up with.


VS25 EGR Vacuum Diagram

After that I buttoned everything back up. It looks pretty decent, plus it won't be such a chore to change if it ever needs swapped again.


VS25 EGR Solenoid final installation

Hitting smog again tomorrow, so I'll post up results. The car ran fine and threw no codes, so fingers crossed!
im going to try this. THERE ARE 4 parts on solenoid.
(Blue)FIRST- I understand pigtail to solonoid
(Green)SECOND- metal nipple connects to vacuum line to TB
***Here is where Iím mixed up. ***. There are 2 black plastic nipples on solenoid right?
(RED) goes to EGR valve
what is the second black plastic nipple for?( that should be next the RED wire in your color coded diagram.??
please help
LAST you said we need the adapter to not mess up the harness. The male clip from the wire coming from my harness is ruined. Iím savvy enough to solder and replace male connection that connects to Adapter you said which connects to solenoid. But I donít now what that piece is called?
i failed smog and mechanic is charging me through the roof to fix this.

Last edited by Dramirezav2016; 03-15-2019 at 02:03 AM.
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Old 03-15-2019, 01:58 AM
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Re: TPI Aftermarket EGR Solenoid Installation

There is usually foam over it, but it's open air vent.

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Old 03-15-2019, 02:20 AM
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by thtanner View Post
There is usually foam over it, but it's open air vent.

Thank you so much. I get it now.
have two more questions.
1.Painless Performance 70402 Weatherpack - is this used for the EGR tempature switch?

2.LT1 Camaro/Firebird/Corvette EGR Solenoid Wiring Harness Connector Plug- is a adapter that works by connecting male end of adapter to solenoid and connection from harness plugs into female end of adapter BUT MY MALE END FROM HARNESS NEED TO BE REPLACED so I can plug into female end of adapter.
WHAT WOULD A REPLACMENT PART FOR THIS BE CALLED?
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Old 03-15-2019, 11:04 AM
  #34  
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Re: TPI Aftermarket EGR Solenoid Installation

Originally Posted by Dramirezav2016 View Post

Thank you so much. I get it now.
have two more questions.
1.Painless Performance 70402 Weatherpack - is this used for the EGR tempature switch?

2.LT1 Camaro/Firebird/Corvette EGR Solenoid Wiring Harness Connector Plug- is a adapter that works by connecting male end of adapter to solenoid and connection from harness plugs into female end of adapter BUT MY MALE END FROM HARNESS NEED TO BE REPLACED so I can plug into female end of adapter.
WHAT WOULD A REPLACMENT PART FOR THIS BE CALLED?
The two connector packs are to make an adapter pigtail for the EGR solenoid, not the temp switch, so it will plug into the standard plug.

If your existing old-style male EGR solenoid connector is messed up, do not worry, the painless 70402 kit includes both sides of the plug. Simply replace your existing plug with the one included in the kit, and make the adapter like I posted above (old-style connector type female to new connector type male)
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Old Yesterday, 09:34 PM
  #35  
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Re: TPI Aftermarket EGR Solenoid Installation

Just want to add that I installed this solenoid on my TPI car today and it's working nicely so far. While bench testing the solenoid, I found that the polarity didn't matter but it does have a + molded into the case, and that it is normally open. I went with an ACDelco 214-357. I picked up a pigtail (PT2830) for it and just spliced it into my harness rather than making an adapter.

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