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Car Forum / Driving, Maintenance, Tuning / Maintenance and Repair / September 2007

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'94 Safari, location of EGR solenoid and thermo switch

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mdevour@eskimo.com - 24 Sep 2007 16:32 GMT
94 Safari, AWD, W engine, PS/PB/AC. Pretty sure I have the 4L60E
trans.

Got three quarters of the way to work the other day when the engine
starts stumbling and wants to stall. Finally realized that something
was upsetting the low idle, causing the oil pressure to drop and the
engine to try to shut down.

Pulled trouble codes 28, 32, and 45.

I removed the EGR valve and found a small piece of carbon-like crud
wedged between the poppet and the housing, preventing the valve from
returning to its closed (?) position. I'm guessing that's the cause of
this episode.

I'd also like to check the EGR control solenoid and thermostatic
vacuum switch, but where are they?

While I'm waiting for your answer I'll be trying to re-plug the air
leak through the intake manifold gasket that causes an IAC error and
racing engine. Pulling the EGR valve disturbed the silicone rubber
patch that kept that problem at bay for the last several years.
<sigh>

Thanks,

Mike D.
Steve W. - 24 Sep 2007 21:08 GMT
> 94 Safari, AWD, W engine, PS/PB/AC. Pretty sure I have the 4L60E
> trans.
[quoted text clipped - 23 lines]
>
> Mike D.

Yep that chunk of carbon did it BUT it will do it again as well. I got
REALLY sick of pulling the EGR on my 94 S-Blazer for the same problem.
Solved it by getting one of the EGR gaskets with a screen over the
pintle. Hasn't bothered since. Another thing you may want to do is give
that engine a top end cleanup with some GM top engine cleaner. That will
break up and blow out a lot of the carbon that causes the problem and
make the engine run cleaner as well.

Just hit the dealer for a can of the liquid cleaner (not the spray
version) and follow the directions. DO NOT USE IT INSIDE A BUILDING and
make sure that the exhaust is aimed away from anything you care about.
It will be throwing a LOT of carbon and crud out and that stuff will
stain anything it hits. Oh and when you first start it and run it to
clear out the cleaner make sure you select an area that is kind of open
and try to pick a day with a breeze. Your van will be creating a smoke
cloud like a tank on the battlefield and you don't want that hanging
around a long time!

Signature

Steve W.
Near Cooperstown, New York

mdevour@eskimo.com - 28 Sep 2007 02:15 GMT
I wrote:
> > 94 Safari, AWD, W engine, PS/PB/AC. ... 4L60E trans.
...
> > I removed the EGR valve and found a small piece of carbon-like crud
> > wedged between the poppet and the housing, preventing the valve from
> > returning to its closed (?) position. I'm guessing that's the cause of
> > this episode of stalling and stumbling.

Steve W. replied:
> Yep that chunk of carbon did it BUT it will do it again as well. I got
> REALLY sick of pulling the EGR on my 94 S-Blazer for the same problem.
> Solved it by getting one of the EGR gaskets with a screen over the
> pintle. Hasn't bothered since.

Ah, that explains the fact we've had *brief* problems like this
before.
I'll have to look for that gasket for the next time.

Never did find where the EGR solenoid and thermostatic vacuum
switch are supposed to be on this engine, but re-patching the intake
manifold leak and re-seating the EGR valve a second time eliminated
the racing engine problem while removing the crud got the low idle
back to normal.

> Another thing you may want to do is give
> that engine a top end cleanup with some GM top engine cleaner. That will
> break up and blow out a lot of the carbon that causes the problem and
> make the engine run cleaner as well.
...
> Your van will be creating a smoke cloud like a tank on the battlefield

I'll have to look into that, Steve. Thanks for the heads-up!

Be well,

Mike D.
boxing@sasktel.net - 28 Sep 2007 04:36 GMT
since you have low oil pressure, check your oil. it might be low.
Steve W. - 28 Sep 2007 23:59 GMT
> I wrote:
>>> 94 Safari, AWD, W engine, PS/PB/AC. ... 4L60E trans.
[quoted text clipped - 32 lines]
>
> Mike D.

On the S Blazer the EGR Solenoid was on the relay strip mounted on the
firewall.

It doesn't take much of a vac. leak to cause the rev. problem.  The
gasket was available online at Rock Auto and my local NAPA had them as well.
Signature

Steve W.
Near Cooperstown, New York

 
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